Pressure Vessel Coster

VESSEL COSTER
Pressure Vessel
Cost Estimating
Program
by
for
3100 South Gessner Road Suite 610

Houston, TX 77063
USA
web site:
Phone:
Fax:
e-mail:
www.codeware.com
713 - 781 - 6636
713 - 781 - 6685
sales@codeware.com
support@codeware.com
LICENSE AGREEMENT
LICENSE AGREEMENT
1)
ACCEPTANCE
By use of the program contained herein, Customer agrees to accept on the following
terms and conditions a nontransferable and nonexclusive license to use this program.
2)
TERM
This Agreement shall be in force from the date Customer purchases this program license
until terminated by Customer or by Codeware. Customer may terminate the agreement
by returning to Codeware the original program, activation device(s), documentation and
any and all copies of disks and documentation. Codeware may terminate this Agreement
upon written notice to the Customer if Customer fails to comply with any of the terms of
this Agreement.
3)
LICENSE
Each program license granted under this Agreement authorizes the Customer to use the
program on one computer installation at a time. The program may be stored on more
than one computer so long as it is in actual simultaneous use on only one computer. Use
on networks is permissable with specific permission and under some restrictions. This
Agreement and any of the licenses, programs, or materials to which it applies may not be
assigned, sublicensed, or otherwise transferred by Customer without prior written
consent from Codeware.
4)
COPYRIGHT
This program may not be reverse assembled or reverse compiled, in whole or in part.
5)
DISCLAIMER OF WARRANTY
This program is provided "as is", without warranty of any kind, either expressed or
implied, including, but not limited to, the implied warranties of merchantability and
fitness for a particular purpose. The entire risk as to the quality and performance of the
program is with you. Should the program prove defective, you assume the entire cost of
all necessary servicing, repair, or correction.
6)
LIMITATION OF LIABILITY
In no event will Codeware be liable for any damages, including any lost profits, lost
savings or other direct, incidental, or consequential damages arising out of the use or
inability to use such program even if Codeware has been advised of the possibility of
such damages, or for any claim by any other party.
< LICENSE AGREEMENT - i >
LICENSE AGREEMENT
7)
GENERAL
If any of the provisions of this Agreement are invalid under statute or rule of law in any
jurisdiction, they are to that extent to be deemed omitted from this Agreement. Any
other act involving reproduction, transfer, use, rental, or other dealing in the original or
copy of the program is prohibited and will violate the terms of the license agreement.
Trademarks
Windows 95, Windows 98, Windows NT, Excel, Access and Word are registered
trademarks of Microsoft Corporation.
HP LaserJet is a registered trademark of Hewlett Packard Company.
Pentium is a registered trademark of Intel Corporation.
Formula One is a registered trademark of Visual Components. This product contains
Formula One from Visual Components. Copyright 1994 - 1997. All rights reserved.
Printing History
Revised May 2004. Changes indicated by revision bars.
The information contained in this document is subject to change without notice.
< LICENSE AGREEMENT - ii >
TABLE OF CONTENTS
TABLE OF CONTENTS
1
LICENSE AGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
INSTALLING COSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware Key Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Coster Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Uninstallating Coster Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-1
1-1
1-2
COSTER QUICK START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Estimate a Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Review the Data Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
USING COSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

How To Use Coster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Coster Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Coster Dialogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Keys used in Coster: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Customizing Coster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Navigating and Modifying the Database Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
FILE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Cost a Codeware File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Costing the Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retrieve Coster Estimate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open or Cancel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backup Coster Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Coster Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-3
4-5
4-5
4-5
4-6
LABOR MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fitup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Rings (layout, fitup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grinding Rates (normal, flush, smooth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Davit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform/Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Saddles (fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skirt Base Ring (layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tray Support Rings (layout, installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-2
5-2
5-2
5-3
5-3
5-3
5-4
5-4
5-5
5-5
5-5
5-5
5-6
MATERIAL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Couplings/Fittings Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
< TABLE OF CONTENTS - i >
TABLE OF CONTENTS
Cylinder Costs (purchased) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flanges (ASME B16.5/16.47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Formed Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe Cost Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Structures/Rings/Tray Supports Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Misc Items (user defined) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stock Plate Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Davit Material Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasket Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform/Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stud Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring Type Joint R Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring Type Joint RX Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-2
6-4
6-4
6-4
6-4
6-4
6-4
6-5
6-5
6-5
6-5
6-6
6-6
6-6
6-6
DEFAULTS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Alias Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Currency/Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Hydrotest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
COSTER SPREADSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

General Spreadsheet Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Insert Miscellaneous Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Customize the Template (CostSS.xls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Coster Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Coster's Estimate Spreadsheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Estimate Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
X-Ray Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Vessel Total Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
Plate Usage (Bill of Materials) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Summary (Create a Customized Report) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
DATABASE TREE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

HELP MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
About Coster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Coster Directories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Database Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
CALCULATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

General Calculations For All Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Interpolation Method Used by Coster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
How Coster Determines Material Layout and Plate Requirements (Default Method) . . . . . . . . . . 11-3
How Coster Determines The Layout of Conical Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
How Coster Determines The Layout of Skirt Base Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Cutting Sketches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Cutting Sketches With Drop Dimensions (includes allowance for squaring of plate) . . . . . . . . . 11-10
Custom Cut Plates (Alternate Material Layout) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
< TABLE OF CONTENTS - ii >
TABLE OF CONTENTS
Purchased Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transition Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Rings Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2:1 Heads, F&D Heads, Hemispherical Heads Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flat Heads Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Flange Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASME B16.5/16.47 and ASME Section VIII Division 1 Appendix 2 . . . . . . . . . . . . . . . . . . . . .
Packed Bed Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform/Ladder and Top Head Platform Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tray Support Ring Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulation/Lining Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Saddles Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skirt Base Ring Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skirt Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leg Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normalization and Impact Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Davit Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grinding Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blasting/Cleaning Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paint/Primer Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrotest Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Post Weld Heat Treatment (PWHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X-Ray Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-16
11-16
11-20
11-23
11-27
11-29
11-35
11-35
11-41
11-41
11-42
11-44
11-46
11-52
11-64
11-68
11-87
11-93
11-94
11-95
11-95
11-96
11-96
11-97
11-97
11-97
APPENDIX A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Coster Database Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
< TABLE OF CONTENTS - iii >
TABLE OF CONTENTS
< TABLE OF CONTENTS - iv >
INSTALLING COSTER
INSTALLING COSTER
System Requirements
Coster requires a Windows 95/98/NT4 Pentium computer or better with:
32 MB RAM minimum and 40 Meg free disk space.
A hardware key supplied by Codeware.
The hardware key, also called dongle or program activator, is needed to operate Coster. The key
plugs into the parallel printer port on the back of your computer. The cable to your printer then
plugs into the key. If the key is not installed, the following error message will be displayed.
Codeware Win 32 Key not found (15)
On some computers this message may also be displayed if the printer is turned off or is not on line.
COMPRESS version 5.x and version 6.x vessel files are compatible with Coster prior to and
including build 963 (December 12, 2003). COMPRESS version 6.x vessel files generating .xml file
output are compatible with Coster builds 964 (February 19, 2004) and later.
Hardware Key Installation

Turn off the computer and printer if the printer is connected. Plug the key into the parallel printer
port of your computer. Reconnect the printer cable and turn the power on. You may find it
convenient to buy a short extension cable and plug the key into the middle of the two cables. This
makes it easier to move the hardware key or to use multiple keys.
Installing Coster Files

Coster is distributed on a self-activating compact disk. To install Coster insert the CD and follow
the prompts as they are presented.
Your computer may have its auto start feature disabled in which case inserting the CD will have no
effect. If this happens, go into Windows Explorer, locate the folder Coster on the CD, enter that
folder, and activate by double clicking the application file setup.exe. This will start the installation
procedure and present you with prompts to follow.
You will need to reboot your computer in order to run Coster the first time.
Network Installation
Coster will operate on Novel or Windows NT Server networks. A different hardware key is required
for network operation. You will be prompted for the type of installation to be performed (i.e., local
or networked) when Coster is installed.
< INSTALLING COSTER 1 - 1 >
INSTALLING COSTER
Uninstallating Coster Files

You may uninstall Coster by using the Coster uninstall option on the program files menu or by using
the Add/Remove Programs option located through the Start/Settings/Control Panel. You may
encounter a few warning messages during program removal as follows:
Error removing program groups
Some components could not be removed from your computer
If files exist in the Coster directory which were not originally installed by Coster, or the
COMPRESS program is installed under the same program group name (usually Codeware), these
messages may appear. Files such as new vessel files (.cw6, and .xml), cost estimates (.xls), and
backup files of the database and spreadsheet template will cause this message to appear. Click OK
and continue with the program uninstallation. These messages will not affect the reinstallation or
operation of Coster.
Do not remove Coster simply by erasing files. This could have unpredictable effects on your
computer.
< INSTALLING COSTER 1 - 2 >
COSTER QUICK START
COSTER QUICK START
This chapter is included to get you up and running with Coster as quickly as possible without having
to worry about all aspects of the program's menus, dialog boxes, methods, etc. These are fully
described in the chapters which follow. Here, we will give you a brief overview of how Coster
works using the Sample1 file.
Estimate a Vessel
Estimate a vessel by clicking on File, then Cost a Codeware File. Choose one of the sample vessels
from the available vessel files by double-clicking. You will be presented with a User Selectable
Items dialog. Select how you want your vessel to be finished and click OK or press F3. (As a
general rule, F3 advances to the next dialog). Now Coster searches for information among its data
libraries. If necessary you will be asked to supply more cost or labor information. Finally, Coster
asks for total x-ray costs. Supply these values and press Enter.
The Vessel Detail Cost sheet of the cost estimate is displayed. You can move about the estimate
using the cursor keys. Notice the level of cost detail that is reported. Notice that the individual
worksheet cells contain not just numbers but formulas. You can change the quantity of most items,
and this change will be reflected in the labor hours and material costs for this item as well as the total
costs for this vessel.
The estimate is divided into three main sections. The first section shows basic vessel elements such
as shells and heads. The second section itemizes nozzles and flanges. The third section presents
miscellaneous items and user defined items which have been added after the estimate is complete.
There is also a "bottom line" summary of labor, material and total cost for the entire vessel.
A Bill of Materials (BOM) is displayed on the second sheet of the estimate. The BOM itemizes all
the parts of the vessel which were considered for costing. The sections of plate used for cylinders
and transitions are listed. Pipe sections required for nozzles are listed. Waste materials are
accounted. There is also a listing of the plate usage (materials used, drop remaining, scrap material)
and associated costs used to fabricate each component. Following the plate usage section is a table
showing the weld type and radiography. Cutting sketches that were used for this vessel are shown at
the bottom of the bill of materials sheet.
A Summary Report is presented on the third sheet of the estimate. The Summary is a means to
display "bottom line values". The Summary is user customizable by modifying the existing
Summary sheet.
Review the Data Tables

Let's look at the data tables which form the basis of Coster's calculations. Click on the "X" button at
the top right of the spreadsheet menu to close the spreadsheet and return to the main menu. From the
main Coster menu select Material, then Plate Costs. This is a typical table. Move the cursor through
the table and you will see costs per 100 lb for each material for various thicknesses and plate widths.
Notice that many of the materials list a non-zero cost for the first thickness and the last thickness
only. Using this information, Coster will interpolate costs for plate thicknesses and plate widths
< COSTER QUICK START 2 - 1 >
COSTER QUICK START
between the non-zero values. Remember that even though there are not many data points Coster
interpolates, so what you see as four data points is really a three-line curve sufficient to convey the
information.
You can change the data and also add information and new materials to this table. To add new plate
costs simply type in the new values (use the Insert Field option on the Edit menu of the database to
add a field to a table). Add as many new materials with corresponding plate width as you wish.
New materials can be added in the cell marked by the asterisk at the bottom of the table. To add new
materials type in the new material name or click the down arrow to select from a list of materials.
Coster will sort the table by material name and then by plate width. The sorted table will be
displayed when the table is reopened.
To view another table click the down arrow on the table drop down box for a list of tables in the
database and select another table. Customize the tables by revising and adding to the default values
provided with your own data.
Click on the drop down box, and select Cylinder Forming Labor. Here we see labor hours required
to form and tack cylinders and cylindrical skirts as a function of thickness and inner diameter.
Welding labor is a special case because it allows you to supply data for either weld deposition rate or
welding rate. Select Labor, Welding, Deposition Rate, Longitudinal Seam from the Main Menu.
You will see weld deposition rate as a function of thickness and metallurgy. There is also a
multiplier for full joint examination in this table.
Go back to the main menu by clicking the OK pushbutton or the "X" button in the top right corner of
the database. Now select the Defaults Menu. Here, you can set all default values for clips (lining,
insulation), currency/units, finishing (blasting/cleaning), hydrotest, other (fabrication, labor rates,
program output, tray supports), and welding (weld detail, diameter/longitudinal weld seams ratio,
fillet welds). You can also make revisions to the alias lists. The alias lists tell Coster that a
particular material can be costed using the same properties as another material. This reduces the
quantity of data which must be supplied for material costs. In addition you may select whether plate
materials will be cut to exact component dimensions without including waste, whether Coster will
select suitable plate sizes and incorporate a waste factor in the associated costs or whether the
cylinders are purchased (formed and tacked only or formed, tacked, and welded).
< COSTER QUICK START 2 - 2 >
USING COSTER
USING COSTER
Vessel Coster estimates the cost of fabrication for pressure vessels. The vessels can be designed
using either COMPRESS or Vessel Modeler.
Coster contains a number of tables of costs, labor hours, and other data to calculate an estimate.
Coster uses this information to automatically produce a final cost estimate in the form of an
Excel-compatible workbook. The tables contain both material and labor data.
Material tables include costs of plate, formed heads, pipe, flanges, weld rod, fittings. Labor tables
contain information on the number of hours required to perform various operations involved in
vessel fabrication. You can customize Coster to your shop's specifications by changing or adding to
the appropriate material or labor table.
How To Use Coster

Coster is written as a true 32-bit Windows program and generally follows Windows terminology and
operating conventions. Therefore, to learn the basics of screen operation, refer to your Windows
documentation. This manual will address operations unique to Coster and will begin with describing
the Main Menu.
Coster Main Menu
Figure 3-1
Coster Main Menu
The Coster Main Menu bar contains the following menu items: File, Labor, Material, Defaults,
Spreadsheet, Database Tree and Help.
While you are costing a vessel, you may be asked to input additional information on a "pop-up"
dialog.
Coster Dialogs
Dialogs are used to provide additional information while costing a vessel and to enter default values
that will be saved and used for subsequent estimates.
< USING COSTER 3 - 1 >
USING COSTER
Keys used in Coster:

-
F2 - Allows you to edit a cell within the spreadsheet.

OK pushbutton - accepts all values input and moves you to the next dialog
F3 -- accepts all values input and moves you to the next dialog (similar to the OK
pushbutton.
Coster uses the following abbreviations when referring to metallurgy:

-
CS = Carbon Steel
SS = Stainless Steel
AL = Aluminum
Cu = Copper
Cu Alloy = Copper Alloy
Ni = Nickel
Ni Alloy = Nickel Alloy
Ti = Titanium
UHT = UHT (ferritic steels with properties enhanced by heat treatment)
Zi = Zirconium
Customizing Coster
Before using Coster, we strongly recommend you invest some time checking the values in the tables
that are relevant to your company. Some editing of the defaults provided with Coster will be
necessary because of your shop's individual circumstances. Before you change any information
presented on Coster's default tables to fit your company's requirements, please refer to Coster
Tables on page 8-6 for guidelines to follow.
Also, because labor and material costs fluctuate over time, occasional revisions will be necessary to
keep your cost information up to date.
Features
Plate Selection
When choosing stock plates to fabricate the vessel, Coster looks at the Compress material used for
the component and tries to find this material on the Plate Costs table, Structures/Rings/Tray
Supports table, and the Material Properties table. If the material is not found Coster will search
through the alias list to find an equivalent alias material that has been previously cross-referenced. If
an alias name cannot be found, Coster will display the Standard Plate Material dialog.
USING COSTER
Figure 3-2
Standard Plate Material
If the material is found on the Material Properties table but the metallurgy has not been entered for
this material then the following dialog is displayed. Select the appropriate metallurgy for the
component described.
Figure 3-3
Metallurgy
With the metallurgy established, Coster looks for a suitable material to fabricate each component
(see Plate Selection on page 3-2). If Coster cannot find a stock plate size that matches both the
thickness and metallurgy, then the Plate Size - User Defined dialog is displayed to enter an
appropriate user defined plate size for estimating this component. The plate size(s) used for
estimating will be listed on the Bill of Materials sheet on the cost estimate. If a user defined plate
USING COSTER
size was used, the letter U will be shown to the left of the plate description on the Bill of Materials
indicating that a user defined plate was used for estimating.
Figure 3-4
Plate Material Size
In our example, Coster was unable to locate a carbon steel material, 1.1075" thick on the Stock Plate
Sizes table. The component being considered and its dimensions are displayed to help you choose an
appropriate plate size for this component.
Enter the desired material width and length. The plate size entered here is "remembered" by Coster
for this estimate only. In other words, the plate size for this material, metallurgy, and thickness will
only have to be input once and may be used for other components in order to estimate the cost of this
particular vessel. Coster assumes that this plate size has unlimited availability. However, if you want
this plate size to be automatically available the next time a vessel is costed, you will need to add it to
the Stock Plate Sizes table (English or Metric).
Because Coster assumes that the length is the critical dimension of the component, girth seams will
not be added unless required due to the stock plate sizes available. If girth seams have been added to
the vessel, the letter G is displayed in the Bill of Materials to the left of the Size of Plate Required to
Cut Each Section column. The following message will also be displayed after the x-ray dialog:
Figure 3-5
Girth Seams Required
USING COSTER
Interpolation
An important feature of Coster is interpolation. Provided a minimum amount of data are available on
a table, Coster can accurately interpolate "in-between" values to use for estimating.
If there is an uncommon size or cost then Coster's interpolation capability should not be relied upon
to calculate the missing value on a table. For cost structures such as these insert a record in the
appropriate table(s) with corresponding prices rather than have Coster interpolate these values.
These "special" costs that you add to your table should not be used as one of the data points in the
interpolations discussed above since these "specialized" costs will be reflected in the interpolated
value. To prevent this, cells surrounding these "specialized" costs (cells above, below, left and right)
should have non-zero values.
Coster will not interpolate values for flange costs or pipe costs as these costs vary greatly depending
upon standard sizes.
If Coster cannot interpolate a value on a table because there is not enough information available you
will be prompted to manually input a value.
Plate Material Alias List
When costing a vessel, an identical match must be made between materials specified in the vessel
file and materials in the Coster tables. This may seem simple until you consider that a single material
may be specified in many ways. For example, the material SA 516 70 could also be called A 516 70
or 516 70 or SA51670. In order to match two material names, Coster removes all spaces,
hyphens (-), greater than symbols (>), less than symbols (<), and equal signs (=) from both names to
see if they are the same. Material names are not case-sensitive, which means they can be uppercase
or lowercase or a mixture of both. Therefore, Coster would identify SA 516 70 and sa51670 as the
same material. To identify the material names A 516 70 and 516 70 with SA 516 70, you can set up
a cross-reference or link between these names by adding them to the alias list in the Defaults - Alias
Lists menu. While estimating, Coster may display a dialog as shown below to allow you to
cross-reference materials (add them to the alias list) during the costing process.
In this example, Coster could not find the plate material A 516 70 (material specified in the vessel
file) in the Coster Plate Costs database table while estimating. The Standard Plate Material dialog is
displayed.
USING COSTER
Figure 3-6
Standard Plate Material
By selecting one of the materials listed (in this example, SA 516 70), Coster cross-references the
two materials and adds the A 516 70 material to the plate alias list. Now these two materials will
always be cross-referenced or linked together for future estimating until you delete the material from
the alias list. The next time the vessel file uses A 516 70 material, Coster will see that it is
cross-referenced to the Coster material SA 516 70. Coster will look up all costing information from
the database tables based on the SA 516 70 material, but the estimate material name will be listed as
A 516 70. This cross-reference is saved in the Alias-Plate/Structures table in the CostDB.mdb
database.
We refer to this cross-reference as an alias name and we differentiate between the vessel file material
and Coster material by referring to them as alias material (vessel file material) and listed material
(Coster material). Therefore, the vessel material A 516 70 becomes an alias name for the Coster
material SA 516 70. The plate listed materials are the materials from each record in the Plate Costs,
Structures/Ring/Tray Supports Material Costs, and Head Costs tables. As materials are added to or
deleted from these tables, the alias materials list will be revised to reflect the changes.
Before you begin estimating vessels, update the alias names by selecting Alias Lists from the
Defaults menu. From this dialog you can update plate, pipe, coupling and flange alias lists. Add
material names that are commonly used in your vessel designs if they are not listed in the Coster
database tables.
Pipe Material Alias List
The Standard Pipe material list appears when a pipe material specified in the vessel file cannot be
located in Coster's pipe cost schedule tables or the pipe alias list. This dialog works in the same way
as the plate alias list. The cross-referenced material names are saved in the Alias-Pipe table.
USING COSTER
Coupling Alias List
The Standard Coupling material list appears when a coupling material specified in the vessel file
cannot be found in Coster couplings costs tables or the coupling alias list. This dialog works in the
same way as the plate alias list. The cross-referenced material names are saved in the
Alias-Coupling table.
Flange Alias List
The Standard Flange material list appears when an ASME B16.5/16.47 flange material specified in
the vessel file cannot be found in Coster's flange costs tables or the flange alias list. This dialog
works in the same way as the plate alias list. The cross-referenced material names are saved in the
Alias-Flange table.
Navigating and Modifying the Database Tables

Print
Select the "Print" option from the File Menu on the Database menu bar to print the current table. The
table will be printed with the date, time and page number. You may print individual records from the
table or the complete table. To select individual records, click in the left margin of the table with
your left mouse button while holding down the Shift key to select a block of records or the Alt key to
select single records.
Insert Record
All records are added at the bottom of the database table. Enter the new information in the record
marked by the asterisk (*) and then press Enter. Coster sorts the table using the first field of the
table. The stud costs, gasket costs, slip on, lap joint, threaded, and socket welded flange costs tables
are sorted using the first and second fields of the table. The long weld neck and blind flange costs
tables are sorted using the first, second, and third fields of the table. The weld neck flange costs
table is sorted using the first, second, third and fourth fields of the table. The sorted table will be
displayed when the table is reopened.
Delete Record
Place the cursor in the record to be deleted, then highlight the whole record by clicking with the
mouse in the left margin. Press the Delete key.
Insert Field
Select Insert Field from the Database Edit menu, enter the new field name in the "Field Name" text
box and select the field that the new field will follow from the "Add After Field" drop down box.
Field names must be inserted in ascending order. Fields may be inserted only if the table is not
currently opened by another user.
USING COSTER
Figure 3-7
Insert Field
Delete Field
Place your cursor on the field to be deleted. Select Delete Field from the Database Edit menu and
click OK. Fields may be deleted only if the table is not currently opened by another user.
Figure 3-8
Delete Field
Split View
The "as-shipped" default used to display the database tables is a "split". The split freezes the first
field of the table so that it is always displayed as you scroll across the remaining fields within the
table. To disable the split, select "Disable Split" from the Format Menu on the Database menu bar.
To enable the split again, select "Enable Split" from the Format Menu.
USING COSTER
Figure 3-9
Split Table
Revising Currency and/or Units on the Database Tables
The currency and/or units of a table may be changed to customize the values to suit your
requirements. Coster will automatically update the table according to the currency and/or units
selected. When tables are displayed with the currency and/or units box "greyed" out this means that
you may not revise the currency/units for these tables. Currency and/or units may be revised only if
the table is not currently opened by another user.
Global Update
The values in the database tables may be updated using the Update Table (global) option on the
database Edit menu. Material costs, labor costs and labor hours may be updated according to the
records that are highlighted. You may select one record by highlighting it or you may select more
than one record or the whole table. Highlight a block of records by holding down the Shift key and
clicking the left mouse button or highlight individual records by holding down the Alt key and
clicking the left mouse button. The values in the records selected will be updated using the
multiplication factor entered. Some tables are updated according to fields rather than records
because of the format of these tables. The fields to be updated are highlighted in the same way the
records are highlighted. This global update option is unavailable for some of the database tables
such as the Misc Items tables.
USING COSTER
Regional Settings
The regional settings for the "as-shipped" Coster database are English (United States). If the
regional settings for your computer are different then Coster will update the database to reflect these
new regional settings. Coster will update the database only if it can be opened exclusively (no other
instances of Coster are running on the network). If there is already another instance of Coster
running on the network and your regional settings are different than the settings on the currently
opened database then the Coster program will not start because of this conflict.
Database Password
You may wish to protect your database by using a password to restrict access to your database.
Currently the password cannot be set within Coster but may be set in Microsoft Access. After you
have saved the database with a password Coster will prompt you for the password before the
program will start. Once you have provided the password Coster will allow you to modify the
database tables and will not prompt you for the password again until you exit and restart the
program.
Lining
If the vessel is lined the following dialog appears:
Figure 3-10
Lining
Lining Cost
Enter the cost of the lining per square foot for the density and thickness indicated.
Lining Labor
Enter the labor hours required to line an area of 100 square feet.
If linings of different densities and/or thicknesses are used on a vessel, the Lining dialog will appear
for each density/thickness variation.
USING COSTER
Insulation
This dialog is similar to the Lining dialog above.
USING COSTER
FILE MENU
FILE MENU
The File menu allows you to perform various operations on vessel files: cost a new file, retrieve a
previously saved cost estimate, backup Coster data, repair the Coster database, or exit the program.
Figure 4-1
File Menu
Cost a Codeware File

This option allows you to cost a Codeware file that has previously been saved.
Select Cost a Codeware File from the File menu. The Codeware Vessel Files dialog appears:
Figure 4-2
COMPRESS Files
Select a file for costing (for example, Sample3). Click Open. You can exit the costing process from
any dialog by selecting the Exit pushbutton.
Once a file is selected, Coster scans all vessel components, searching for the information
(metallurgy, plate thickness, diameter) required to determine a suitable material layout.
Coster then proceeds to the User Selectable Items dialog.
< FILE MENU 4 - 1 >
FILE MENU
Figure 4-3
User Selectable Items
The components affected by the inputs on this dialog are heads, cylinders, transitions, skirts and
skirt base rings. Studs and gaskets are estimated for all nozzles with blind flanges using the
information provided on this dialog. Weld neck, long weld neck, and blind flange costs are
determined in part according to the facing selected on this dialog. Just below the studs and gaskets
section a message is displayed to indicate whether the cylinders are fabricated, purchased formed
and tacked only, or purchased formed, tacked, and welded.
Cylinder -- Coster displays the method used for estimating cylinders. They may be
fabricated in house, purchased formed and tacked only or purchased formed, tacked and
welded.
Primer and Finish Painting -- Select the type of primer or paint to be used for
estimating this vessel. The primer/paint types listed are from the Painting and Primer
database tables. Check "Inside" and/or "Outside" to indicate how to prime or paint the
above components.
Coats of Primer/Paint -- Enter the number of primer/paint coats to be applied. If the
number of primer/paint coats entered is zero then no priming/painting will be
considered.
Paint and Prime Stainless Steel Materials -- The default for this checkbox is
"unchecked". If "unchecked" then paint and primer applied to the vessel will include
< FILE MENU 4 - 2 >
FILE MENU
only those components made from carbon steel material. If "checked" then paint and
primer applied to the vessel will include components made from both carbon steel and
stainless steel materials.
Cleaning Method -- Select the desired metal surface preparation method. This list is
formed from the methods entered on the Blasting/Cleaning dialog which may be selected
from the Defaults - Finishing menu.
Grinding Method/Inside and Grinding Method/Outside -- Select the type of grinding to
be applied to all welds on the inside and outside of the vessel.
Stud material (used with ASME B16.5/16.47 flanges) -- Select the stud material used
for estimating this vessel. This list of stud materials displays all the materials found on
the Stud Cost table.
Gasket material (used with ASME B16.5/16.47 flanges) -- Select the gasket material
used for estimating this vessel. If the Flange Facing selected is RF then the list of gasket
material displays all the materials found on the Gasket Cost table. If the flange facing
selected is RTJ (ring type joint) and the ring type selected is R then the list of gasket
material displays all materials found on the Ring Joint R Cost table. If the flange facing
selected is RTJ and the ring type selected is RX then the list of gasket material displays
all materials found on the Ring Joint RX Cost table.
Flange facing (used with ASME B16.5/16.47 flanges) -- Select the flange facing (RF or
RTJ) used for estimating this vessel. If the flange facing selected is RF (raised face) then
the ring type is disabled. If the flange facing selected is RTJ then the ring type is active.
Ring type (used with ASME B16.5/16.47 flanges) -- Select the ring type (R or RX)
used for estimating RTJ gaskets. This selection is available only if the flange facing
selected is RTJ.
Costing the Vessel

Coster considers all vessel components, attachments, and nozzles that make up the vessel. Coster
searches the data tables for density, weld rod cost, impact testing, normalization, labor, and material
costs. If Coster cannot find the information it needs and cannot interpolate a value, then you will be
prompted for more information.
If Coster cannot find the vessel material in its database tables or in the alias lists, you will be
prompted to enter an alias name for this material.
If Post Weld Heat Treatment (PWHT) is required on this vessel for any component(s) an entry for
PWHT will be shown on the estimate. Coster determines that "global" PWHT is required if the
following components all require PWHT -- ASME B16.5/16.47 body flange, ASME Section VIII
Division 1 Appendix 2 flange, 2:1 head, f&d head, hemi head, flat welded head, transition, cylinder.
Otherwise if PWHT is required on some but not all of these components then Coster determines that
"local" PWHT is required. If global PWHT is determined then Coster will also add the weight of the
< FILE MENU 4 - 3 >
FILE MENU
saddles, skirt base ring and compression ring, legs (including leg base plate and leg pad), skirts, and
vacuum rings to the weight of the welded components. If the ASME B16.5/16.47 body flange
requires PWHT then the blind weight will be added to the weight of the welded components.
Similarly the weight of the pad will be added if the nozzle to which it is attached requires PWHT.
Global PWHT is calculated by multiplying the weight of the welded components by the cost per 100
lb user-defined default from the Fabrication dialog on the Defaults - Other menu. The total PWHT
and the weight of the welded components will be displayed on the estimate. If local PWHT is
required you will be asked to enter a total cost for PWHT during the estimating process. The weight
will not be displayed on the estimate for local PWHT.
Figure 4-4
Local PWHT
The x-ray dialog is the last dialog displayed before the estimate.
Figure 4-5
< FILE MENU 4 - 4 >
Total X-ray Cost
FILE MENU
Total X-Ray Cost -- Enter the cost of x-ray for the entire vessel. Coster calculates the
total weld lengths based on the type of weld and type of radiography (full, spot, none) for
the vessel and displays these totals as a guide when entering the total x-ray cost. This list
of welding information is also displayed on the estimate at the bottom of the Bill of
Materials sheet.
Retrieve Coster Estimate
Figure 4-6
Retrieve Coster Estimate
File name -- Enter the name of the workbook (with a .xls extension) to retrieve.
Files of type -- The type of files displayed are Microsoft Excel Files (*.xls)
Open or Cancel
Select Open to retrieve the .xls workbook. Select Cancel to return to the main menu without
retrieving a workbook.
Backup Coster Data

Select Backup Coster Data from the File Menu to back up the CostDB.mdb and CostSS.xls files.
< FILE MENU 4 - 5 >
FILE MENU
Figure 4-7
Backup Coster Data
Select the drive and directory to back up your files. Coster will create a copy of the CostDB.mdb
and CostSS.xls files in the selected directory. The names of these files will be CostDBbk.mdb and
CostSSbk.xls respectively. This option is only available if the database can be opened exclulsively
(no other instances of Coster are running on the network).
Repair Coster Database

This option will reduce the size of your database so you may select this option periodically to
maintain a more reasonable size for your database.
This option will also attempt to repair a database file that has been marked as possibly corrupt by an
incomplete operation. This may occur due to a power outage or computer hardware problem. This
option will validate all tables and indexes, and any data that cannot be repaired will be discarded.
An error will be displayed if the database cannot be repaired. Choose this option if your database is
behaving unpredictably.
This option is only available if the database can be opened exclusively (no other instances of Coster
are running on the network).
< FILE MENU 4 - 6 >
LABOR MENU
LABOR MENU
The Labor menu accesses Coster default labor tables.
Figure 5-1
Labor Menu
Fitup
The following fitup labor tables are included: cylinder/cylinder, cylinder/transition, flat
welded head (sketches (c), (e), (f), (g), (h)), formed head/cylinder (includes formed
heads and flat welded head sketches (b-1), (b-2), (d))), nonradial nozzle, skirt. These
tables contain labor hours to fit up one component to another based on component
thickness and diameter. The diameter and thickness used to read the labor hours from
these tables will be determined as follows: cylinder/cylinder fitup will look up the
thickness and diameter of the cylinder with the larger OD (if the OD's are equal then use
the first cylinder thickness and diameter), cylinder/transition will use the cylinder
thickness and diameter, flat welded head will use the head thickness and head OD,
formed head/cylinder will use the cylinder thickness and diameter, and skirt fitup will
look up the thickness and diameter at the top of the skirt. The nonradial nozzle fitup is a
factor based on the radial angle (degrees) which is used to increase the nozzle installation
labor hours for nonradial nozzles.
Forming
Cylinder/Straight Skirt -- The Cylinder Forming Labor table displays the labor hours
required to form cylinders, straight skirts and fabricated nozzles as a function of
component thickness and component ID.
< LABOR MENU 5 - 1 >
LABOR MENU
Transition/Conical Skirt -- The Cones and Skirts Forming Labor table displays the
labor hours required to form cones and conical skirts as a function of component
thickness and component ID.
Heads
Bevel (all heads) -- The Head Bevel Labor table contains labor hours to bevel the head.
These labor hours will be included in the Forming Labor column of the estimate.
Layout (flat welded head) -- The Head Flat Layout Labor table contains labor hours to
lay out flat welded heads based on head thickness and head OD.
Machining (flat welded head) -- The Head Flat Machining Labor table contains
machining labor hours for flat welded heads based on groove depth and head OD.
Vacuum Rings (layout, fitup)

The Vacuum Ring Labor table displays the labor hours required to lay out and fit up vacuum rings as
a function of vessel OD.
Nozzle Installation
Figure 5-2
Nozzle Installation Submenu
The labor costs for nozzles are calculated using the manufacturing labor cost default from the Labor
Rates dialog on the Defaults - Other menu (see page 7-6).
Coupling to Vessel -- The Coupling Installation Labor table displays the labor hours
required to install, layout and fitup couplings as a function of coupling type, vessel
thickness and coupling nominal size.
LABOR MENU
Boltup Blinds -- The Blind Flange Labor table displays the labor hours required to
attach a blind flange as a function of flange size and class. If a blind flange is not
attached to a nozzle, hydrotest labor hours are calculated by using the blind flange labor
multiplied by 2.
Flange to Nozzle -- There are two separate Flange to Nozzle Labor tables - fitup labor
and welding labor. These tables contain flange fitup or welding labor hours as a function
of flange type (weld neck flange or other ASME B16.5/16.47 flange except long weld
neck flanges and HB types), metallurgy, nozzle OD and pipe schedule. A field for
nominal size has been included for informational purposes only. Fields and records must
not be added or deleted from these tables.
Nozzle/Long Weld Neck -- The Nozzle to Shell or Head Labor table displays the labor
hours required to attach the nozzle or long weld neck (layout, fitup) to the shell or head
as a function of vessel thickness and nozzle OD.
Pad to Nozzle/Long Weld Neck -- The Pad to Nozzle Labor table displays the labor
hours required to attach the pad (layout, fitup) to the nozzle or long weld neck as a
function of pad thickness and nozzle OD.
Grinding Rates (normal, flush, smooth)

The Grinding Labor table displays the grinding rates as a function of metallurgy, grinding type
(normal, flush or smooth grinding) and component thickness. This table is used for cones, skirts,
heads, and cylinders according to the long seam and circumferential seam weld lengths.
Fabrication
Misc (cutting, welding supports, drilling, bevelling) -- The Miscellaneous Fabrication
Labor table displays labor hours for various operations such as cutting, fillet and groove
welding, and drilling as a function of metallurgy and component thickness. These
cutting and fillet welding rates are used for estimating saddles and these cutting, drilling,
fillet welding, groove welding, and gusset welding rates are used for estimating skirt
base rings. The bevelling field is used to calculate labor hours for the seams on
cylinders, transitions, and skirts.
Drilling -- The Drilling Labor table displays drilling labor for appendix 2 flanges.
Machining -- The Machining Labor table displays labor hours for appendix 2 flanges.
Davit
The Davit table is actually one table containing davit cost, labor hours, and weight, but within Coster
it appears as if there are three separate tables (one table for davit material costs, one for davit labor
hours and one for davit weight). Each field heading displays the class and the type of davit
information -- cost, labor, or weight. Fields and records may be inserted and deleted through the
Edit menu on the Coster database. When adding fields Coster automatically adds "# cost",
LABOR MENU
"# labor", or "# weight" to the class field name entered by the user to complete the field heading.
Using the data in this table Coster calculates the material cost, labor hours, and weight of each davit
for manway openings. The davit weight is listed on the Bill of Materials sheet in the estimate, and
the material costs and labor hours are displayed in the Miscellaneous section of the Vessel Detail
Cost sheet. The Davit cost table can be accessed through the Material menu and the Davit Labor and
Davit Weight tables can be accessed through the Labor menu.
To include davits in the estimate, check the "Always Add Davits" checkbox and enter a value for
"Minimum Manway Diameter Required to Add Davits" on the Fabrication tab of the
Defaults - Other menu. Davits will then be estimated for all manway openings equal to or larger
than the minimum specified.
Finishing
Paint
The Paint (finishing) table contains material costs and labor hours for each paint type. As the paint
labor rate does not vary according to paint type there is only one labor rate which is located on the
Defaults - Other menu Labor Rates dialog.
Paint Application Labor -- The time required to apply 1 coat of paint to 100 square
feet of vessel surface.
Paint Cost -- The cost per gallon of the paint being used.
Paint Coverage -- The number of gallons of paint required to cover 100 square feet of
vessel surface.
Paint Standard Container Size -- If you enter a zero for standard container size,
Coster will report the paint material cost based on the exact quantity of paint used. If the
standard container size entered is anything other than zero, Coster rounds the quantity of
paint used up to the next standard container size. This is done because leftover paint
cannot usually be used for the next project.
Primer
The Primer table is contains material costs and labor hours for each primer type similar to the paint
table above. As the primer labor rate does not vary according to primer type there is only one labor
rate which is located on the Defaults - Other menu Labor Rates dialog.
Legs
The submenu for Legs includes the following tables: Legs Labor, Legs Labor - Base Plate, and Legs
Labor - Pad. The Legs Labor table contains labor hours to layout/burn, fitup, and weld legs based
on the leg major dimension. The Legs Labor - Base Plate table contains labor hours to layout and
fitup the base plate based on the base plate major dimension. The Legs Labor - Pad table contains
labor hours to layout and fitup the pad based on the pad major dimension. The leg, base plate, and
LABOR MENU
pad major dimensions are determined by comparing the length and width (or in the case of the leg
compare the width and depth) and using the larger dimension as the major dimension.
Platform/Ladder
The Platform/Ladder Cost and Labor table contains material costs and labor hours for platforms,
railings and ladders. Since this table contains both material costs and labor hours it can be accessed
from both the Labor and Material menus. Using the data in this table Coster calculates platform,
railing, and ladder material costs, labor hours, and labor costs for display in the Miscellaneous
section of the estimate. The weights of these items are listed on the Bill of Materials in the estimate.
Saddles (fitting)
The Saddles Fitting Labor table displays labor hours to fit the saddle and wear plate as a function of
vessel OD.
Skirt Base Ring (layout)

The Base Plate Layout Labor table displays the labor hours to install the carbon steel skirt base plate.
This includes labor hours to lay out and fit up the base plate as a function of base plate ID and the
number of ring segments.
Tray Support Rings (layout, installation)

The Tray Installation Labor table displays the labor hours required to lay out and install tray support
rings as a function of vessel ID.
LABOR MENU
Welding
Figure 5-3
Welding Time Submenu
Time to Weld Submenu -- These tables (Welding Time - Circumferential Seam Weld,
Welding Time - Longitudinal Seam Weld, Welding Time - Nozzle Fillet Weld and
Welding Time - Nozzle Groove Weld) are not directly used by Coster for estimating but
are included for users that have data for welding in minutes/ft rather than lb/hr. The
function of these tables is to allow a conversion from minutes/ft values to lb/hr values
based on the weld type, thickness, metallurgy and defaults set in the Conversion Weld
Defaults dialog (see Figure 5-4). You will be asked if you want to convert these values
when you switch to another database table. The converted lb/hr values are saved in the
corresponding deposition rate table -- Weld Deposition Rate - Circumferential Seam
Weld, Weld Deposition Rate - Longitudinal Seam Weld, Weld Deposition Rate - Nozzle
Fillet Weld, Weld Deposition Rate - Nozzle Groove Weld. If the deposition rate tables
have been updated using the minutes/ft values, a note appears at the bottom of the
deposition rate table to identify the defaults used to convert the minutes/ft values to lb/hr.
These deposition rate tables are the tables used by Coster to calculate welding. If you
have welding rates available in lb/hr, it is not necessary to enter information into these
"Welding Time" tables; enter the lb/hr rates directly into the appropriate deposition rate
table.
The parameters used to convert from minutes/ft to lb/hr are contained on the Conversion
Weld Detail dialog.
LABOR MENU
Figure 5-4
Conversion Weld Detail
The values on this dialog will be used only to convert the minutes/ft welding rates in the
"welding time" tables to lb/hr rates in the "deposition rate" tables. The values used for
estimating a vessel are saved from the Weld Detail tab of the Defaults menu. The
definitions of the conversion weld details and the estimating weld details are identical
and are described beginning on page 7-10. The Weld Reinforcement table contains data
indicating the height of the weld bead projecting beyond the surface of the parts being
welded. This table is used for both converting the minutes/ft values to lb/hr and also for
estimating the cost of a vessel.
Welding Time
Circumferential Seams (Welding Time) -- The Welding Time - Circumferential Seam
Weld table displays circumferential seam welding time in minutes/ft for single v or
single u welding as a function of metallurgy and thickness. Also included on this table is
a full rework multiplier based on the thickness (included to increase the labor hours for
full joint examination) which will be transferred from the welding time table to the weld
deposition rate table when the lb/hr conversions are made.
Longitudinal Seams (Welding Time) -- The Welding Time - Longitudinal Seam Weld
table displays longitudinal seam welding time in minutes/ft for for single v or single u
welding as a function of metallurgy and thickness. Also included on this table is a full
rework multiplier based on the thickness (included to increase the labor hours for full
joint examination) which will be transferred from the welding time table to the weld
deposition rate table when the lb/hr conversions are made.
Nozzles (Welding Time) -- Fillet/Groove -- The Welding Time - Nozzle Fillet Weld
and Welding Time - Nozzle Groove Weld tables display welding time in minutes/ft
LABOR MENU
based on metallurgy, nozzle OD, and weld thickness (nozzle groove weld) or weld leg
size (nozzle fillet weld).
Deposition Rate Submenu
Figure 5-5
Weld Deposition Rate Submenu
Circumferential Seam (Cylinder/Heads) -- The Weld Deposition

Rate - Circumferential Seam Weld table Deposition Rate displays the circumferential
seam weld deposition rate as a function of metallurgy and component thickness. There
is a full rework multiplier included based on the thickness which is used during
estimating to increase the labor hours for full joint examination.
Longitudinal Seam (Cylinder) -- The Weld Deposition Rate - Longitudinal Seam Weld
table displays the longitudinal seam weld deposition rate as a function of metallurgy and
component thickness. There is a full rework multiplier included based on the thickness
which is used during estimating to increase the labor hours for full joint examination.
Nozzles -- The Weld Deposition Rate - Nozzle Fillet Weld and Weld Deposition
Rate - Nozzle Groove Weld tables display the weld deposition rate for manual welding
as a function of metallurgy, weld thickness and nozzle OD.
Note: If you do not have data for lb/hr values, refer to Welding Time on page 5-7 for
information on converting minutes/ft values to lb/hr. These tables are used to calculate
the long seam and girth seam labor hours for skirts, cones, cylinders, flat heads, and
nozzle from plate material and to calculate the labor hours to weld nozzles.
MATERIAL MENU
MATERIAL MENU
The Material menu accesses Coster default material costs tables.
Figure 6-1
Material Menu
Couplings/Fittings Cost
The Couplings Costs table contains pricing for 3000# and 6000# couplings as a function of material
and coupling nominal size.
Cylinder Costs (purchased)

Formed and Tacked -- The Cylinder Costs (formed/tacked) table contains pricing for purchased
cylinders based on material, length and thickness and cylinder OD.
Formed, Tacked and Welded -- The Cylinder Costs (welded) table contains pricing for purchased
cylinders based on material, length and thickness and cylinder OD.
< MATERIAL MENU 6 - 1 >
MATERIAL MENU
Flanges (ASME B16.5/16.47)
Figure 6-2
Flanges (ASME B16.5/16.47)
These tables contain flange costs for each table as follows:

a)
blind and long weld neck flange costs as a function of flange size according to the
material, class, and flange facing selected
b)
slip on, lap joint, threaded and socket welded flange costs as a function of flange
size according to the material and class selected.
c)
weld neck flange costs as a function of flange size according to the material, class,
bore size, and flange facing selected
Long Weld Neck -- Flange Costs, Flange Specs, Cutting Fee
There are six selections for long weld neck flanges. Each long weld neck type has a separate table
containing flange costs as a function of flange size according to the material, class, and flange facing
specified.
MATERIAL MENU
Figure 6-3
Long Weld Neck Types
For each long weld neck flange type and class there is a separate Flange Specs table containing
standard length, and cost per 1" length as a function of flange size and class to be used for welding
calculations.
Density, weld rod cost and metallurgy will be read from the Material Properties table based on the
material to which the LWN is attached.
Long weld neck flanges that are shorter than the standard length will be priced according to the
standard length plus a cutting fee to cut it to the required length. Long weld neck flanges that are
longer than the standard length will be priced according to the standard length plus a cost for the
extra length plus a cutting fee to adjust the flange to the required length. Coster assumes that long
weld neck flanges can be purchased in lengths beginning at 12 inches and incremented by 2 inch
lengths (12 inches, 14 inches, 16 inches, etc.). Calculate the extra length by subtracting the standard
length from the purchased length and multiply this extra length by the cost per 1" lengths value from
the flange specs table.
The cutting fee used to adjust the long weld neck to the required length is read from the Flange
Cutting Fee - Long Weld Neck table based on the flange nominal size and long weld neck type
(standard, heavy barrel, etc.).
MATERIAL MENU
Formed Heads
Figure 6-4
Formed Heads Submenu
The head tables contain head costs based on material, head thickness and head OD.
Pipe Cost Schedule

The pipe table contains pricing based on material, pipe schedule and pipe nominal size.
Plate Costs
The Plate Costs table contains pricing for plate materials as a function of material, width and
thickness.
Structures/Rings/Tray Supports Cost

The Structures/Rings/Tray Supports Material Costs table contains pricing for structures/rings/tray
supports based on the type of structure/rings/tray supports.
Material Properties
The Material Properties table includes data for material density, welding rod density, welding rod
cost, normalization premium, impact testing, and metallurgy.
Misc Items (user defined)

Misc Items 1 -- The Misc Items 1 table displays a list of miscellaneous items (davits,
vortex breakers) and their corresponding unit weight, labor requirement, and cost that
MATERIAL MENU
may be added to the Vessel Detail Cost sheet in the Miscellaneous section of the
estimate. Additional items may be added to this table or additional "misc items" tables
may be created if you choose to group similar items together into one table. The order of
the columns on this table must match those in the Miscellaneous section of the Vessel
Detail Cost sheet and must not be changed. For more information on creating additional
"misc items" tables, refer to Insert Miscellaneous Items on page 8-1. Miscellaneous
items that are required on all estimates should be added to the Misc Items Auto table.
Misc Items Auto -- Coster includes a Misc Items Auto table that contains material costs
and labor hours for items to be included on every vessel estimated. Similar to the Misc
Items 1 table, the columns on this table must match those in the Miscellaneous section of
the Vessel Detail Cost sheet and must not be changed. More items may be added to this
table, and you may revise or delete the name plate record to suit your requirements. The
difference between this table and the Misc Items 1 table is that all items from the Misc
Items Auto table will be added automatically by Coster to the miscellaneous section of
each estimate so that these items do not need to be added manually each time.
Stock Plate Sizes

The Stock Plate Sizes table contains available plate sizes used to estimate cylinders, skirts, cones,
nozzles, and pads from plate material. There are two Stock Plate Sizes tables -- one in English units
and one in Metric units. If a vessel has been saved in metric units then Coster will read the Metric
stock plate sizes table to determine a suitable plate size for fabricating components. Vessels saved in
English units will read the English stock plate sizes table.
Davit Material Cost

Refer to Davit on page 5-3 for a description of this table.
Finishing
Refer to Finishing on page 5-4 for a description of these tables.
Gasket Cost
The Gasket Costs table contains cost per gasket (used with ASME B16.5/16.47 flanges) based on the
gasket type, flange nominal size, and class. These costs are for gaskets with RF (raised face) flange
facing. Ring type joint gasket costs are read from the Ring Joint Cost tables according to the ring
type. Records may be added to this table and the table will be sorted according to gasket type and
flange nominal size when it is reopened. Fields may not be added to this table. To update the costs
on the table using the Update Table (global) option from the database Edit menu highlight the
records to be updated. Gasket type is selected from a drop down box on the User Selectable Items
dialog and will be used for estimating all gaskets. The gasket types are selected from the gasket
types in the Gasket Costs table. The gasket types are selected from the gasket types in the Gasket
Costs table. The flange facing and ring type are also selected from the User Selectable Items dialog.
If there is a blind flange present then gasket costs will be estimated and added to the Miscellaneous
section of the Vessel Detail Cost sheet. No interpolation will be made for gasket costs. Gasket costs
MATERIAL MENU
are combined on the Vessel Detail Cost sheet if the gasket type and gasket cost are identical. Coster
determines the ring size according to the class, flange nominal size, flange facing, and ring type
using an internal data chart. Gaskets are listed in the Bill of Materials and are combined if the gasket
type, flange nominal size, class, flange facing, ring type, and ring size are identical.
Platform/Ladder
Refer to Platform/Ladder on page 5-5 for a description of this table.
Stud Cost
The Stud Costs table contains cost per stud, including 2 hex nuts, based on the stud material, stud
bolt length, and stud diameter. Records may be added to this table and the table will be sorted
according to stud material and stud bolt length when it is reopened. Fields may not be added to this
table. To update the costs on the table using the Update Table (global) option from the database Edit
menu highlight the records to be updated. Stud material is selected from a drop down box on the
User Selectable Items dialog and will be used for estimating all studs. The stud materials are
selected from the materials in the Stud Costs table. The flange facing and ring type are also selected
from the User Selectable Items dialog. If there is a blind flange present then stud costs will be
estimated and added to the Miscellaneous section of the Vessel Detail Cost sheet. No interpolation
will be made for stud costs. Coster determines the number of bolt holes, stud diameter, stud bolt
length and ring size according to the class, flange nominal size, flange facing, and ring type using an
internal data chart. Stud costs are combined on the Vessel Detail Cost sheet if the stud material and
stud cost are identical. Studs are listed in the Bill of Materials and are combined if the stud material,
flange nominal size, class, stud bolt length, stud diameter, and flange facing are identical. Weight of
source material for studs in the Bill of Materials is calculated as
stud quantity x (stud diameter / 2)^2 x x stud length x carbon steel density
Ring Type Joint R Cost

The Ring Type R Cost table contains cost per ring type joint based on material and R number (ring
size). Records may be added to this table and the table will be sorted according to stud material and
stud bolt length when it is reopened. Fields may not be added to this table. To update the costs on
this table using the Update Table (global) option from the database Edit menu highlight the records
to be updated. If there is a blind flange present and the ring type specified on the User Selectable
Items dialog is RTJ then ring type joint gasket costs will be estimated and added to the
Miscellaneous section of the Vessel Detail Cost sheet. No interpolation will be made for ring type
joint costs. Coster determines the R number according to the class, flange nominal size, flange
facing, and ring type using an internal data chart.
Ring Type Joint RX Cost

The Ring Type RX Cost table contains cost per ring type joint based on material and RX number.
Records may be added to this table and the table will be sorted according to material when it is
reopened. Fields may not be added to this table. To update the costs on this table using the Update
Table (global) option from the database Edit menu highlight the records to be updated. If there is a
MATERIAL MENU
blind flange present and the ring type specified on the User Selectable Items dialog is RTJ then ring
type joint gasket costs will be estimated and added to the Miscellaneous section of the Vessel Detail
Cost sheet. No interpolation will be made for ring type joint costs. Coster determines the RX
number according to the class, flange nominal size, flange facing, and ring type using an internal
data chart.
MATERIAL MENU
DEFAULTS MENU
DEFAULTS MENU
Select one of the options on the defaults menu to set user defined values. The information entered
on these dialogs will be saved and used as defaults for estimating until further revisions are made.
Alias Lists
Select Alias Lists to make changes (add/delete) to the alias lists for plate, pipe, coupling and flange
materials. The alias lists creates a cross-reference between materials contained in the Coster tables
and materials used to design the vessel. Once established, each time a material is located on a vessel
during the costing procedure, it will be matched with its "alias" on the data tables, even though they
may not be specified identically in both places (for example, the materials SA 516 70 and A 516 70).
Plate Materials
Select Plate to add, edit, or delete alias names for plate materials in the Plate Costs, Structures/
Rings/Tray Supports Material Costs, Head Costs - 2:1, Head Costs - F&D, and Head
Costs - Hemispherical tables.
Figure 7-1
Plate Cross Reference
Plate Materials - Alias Name for Selected Coster Material -- Select an alias name
from the materials in the drop down list to correspond with the material name
highlighted in the Coster Name list. The drop down list of materials is created from the
COMPRESS or Modeler asme.mdb and user.mdb files (see "Materials" in the
COMPRESS manual).
< DEFAULTS MENU 7 - 1 >
DEFAULTS MENU
Coster Name -- This is a list of the materials from the Plate Costs, Structures/Rings/
Tray Supports Material Costs, Head Costs - 2:1, Head Costs - F&D, and Head
Costs - Hemispherical tables. Click on the material name you wish to link or
cross-reference to one or more vessel alias name(s). After creating this cross-reference,
each time Coster encounters one of the "alias" names, it will use the properties of the
highlighted material for estimating but will display the actual material name from the
vessel file in the estimate.
Alias Name(s)
There are two ways to add alias names to this list:

1)
Material names selected from the "Alias Name for Selected Coster Material" drop
down list will be added to the Alias Name(s) list and cross-referenced to the
material name highlighted in the Coster Name list.
2)
Materials selected from Standard Plate Material on page 3-3 during costing will
automatically be cross-referenced to the material specified and added to the alias
list.
Add Alias/Delete Alias/Clear Alias List
Click on Add Alias to add the material name specified in the "Alias Name for Selected Coster
Material" input box to the Alias Name(s) list.
Highlight a material to be removed from the Alias Name(s) list box. Click on Delete Alias to
remove the material name specified.
The Clear Alias pushbutton will delete all names in the Alias Name(s) list box corresponding to the
highlighted material in the Coster Name list.
This list of cross-referenced plate materials is saved in the Alias - Plate/Structures table in the
CostDB.mdb database file.
Pipe
The pipe alias option is similar to the plate alias option. The Coster Name list includes material
names from the Pipe Cost Schedule database table. This list of cross-referenced pipe materials is
saved in the Alias - Pipe table in the CostDB.mdb database table.
Coupling
The coupling alias option is similar to the the plate alias option. The Coster Name list includes
material names from the Coupling Costs table. This list of cross-referenced plate materials is saved
in the Alias - Coupling table in the CostDB.mdb database file.
DEFAULTS MENU
Flange
The flange alias option is similar to the the plate alias option. The Coster Name list includes
material names taken from all flange cost database tables. This list of cross-referenced plate
materials is saved in the Alias - Flange table in the CostDB.mdb database file.
Clips
Insulation Clips
Insulation Coverage -- The area which is held in place by one clip. Coster uses this
information to determine the total number of clips required to attach the insulation.
Insulation Clips -- Enter the cost of one insulation clip.
Insulation Clip Labor -- Enter the labor hours required to install one insulation clip.
Insulation is shop installed -- Indicate that all insulation is shop installed.
Insulation is field installed -- Indicate that all insulation is field installed.
Lining Clips
The Lining Clips dialog is similar to the Insulation Clips dialog.
Currency/Exchange
Select Currency/Exchange to set currency names along with their corresponding exchange rates and
currency symbol for the estimate. These settings will be used for estimating and displaying the
estimate until revisions are made.
DEFAULTS MENU
Figure 7-2
Set Currency/Exchange Rate
Currency -- Enter the names of the currencies you require. The $US (base currency) is
displayed and cannot be changed. All other currencies are user defined so any currencies
may be entered.
Exchange Rate -- All currency is based on the United States equivalent. Enter the
exchange rate for a particular currency here. For example, an exchange rate of 1.45
beside Canadian currency shows the following relationship between Canadian and
United States currencies.
$1 CDN X 1.45 = $1 US
If all table costs are in $US and the estimate currency selected is $CDN, Coster will
convert the values to Canadian currency based on the exchange rate specified on this
dialog.
Report Currency -- Select the currency to be used for displaying the final estimate
from this list. The currencies specified in the Currency column automatically appear in
this list.
Defaults Menu Units -- Select the units to be used for entering the user defined
defaults on the Defaults menu.
DEFAULTS MENU
Finishing
Blasting/Cleaning
Blasting/Cleaning Method -- Enter the blasting/cleaning methods and hours required

to clean or blast an area of 100 square feet.
These blasting/cleaning methods are listed on the User Selectable Items dialog which
appears during estimating. The labor hours entered here as user defined blasting/
cleaning defaults are used to estimate the blasting/cleaning on the estimate.
Hydrotest
Hydrotest Factor (a, b, c) -- Coster calculates hydrotest hours for the main vessel
using the following formula.
Hydrotest hours = a * ID2 * L + b * ID + c * L
where:
ID = inner diameter in feet
L = component length (axial length for cones) in feet
Enter values for a, b, and c in the hydrotest factor fields. If you enter 0 in all three fields,
hydrotest will not be considered, even for nozzles.
If the vessel design does not include blind flanges on each nozzle, the time to attach and
remove a blind flange is calculated and added to the hydrotest hours.
DEFAULTS MENU
Other
Figure 7-3
Fabrication, Defaults - Other
Fabrication
Minimum Shell Course Length -- Enter the smallest acceptable width of plate
material that can be used when piecing together a component. When a component must
be pieced, Coster uses sections of plate whose width is equal to or larger than the
minimum shell course length specified. The minimum shell course length applies to
both circumferential and longitudinal seams.
To show you how this works, let's assume that the minimum shell course length has been
specified as 12". We are going to construct a cylinder with a 48" diameter and
96" length from plate material that is 48" x 96". This would require three plates
48" x 96", with a section of 6.797" x 96" left to complete the cylinder. However, this
6.797" wide piece is narrower than the specified minimum shell course length (12") so
this method of fabrication would not be acceptable. Coster could instead choose a larger
plate size, for example, 84" x 96" and cut the cylinder from two pieces of plate.
Cut Width (waste from flame cutting) -- When a pad is cut, a certain amount of
material is wasted. Enter the amount of wastage that will occur around the perimeter of
the pad. This value is also used to calculate the wastage of the skirt base ring and is used
when Coster selects the plate sizes to fabricate components (refer to How Coster
Determines Material Layout and Plate Requirements (Default Method) on page 11-3).
When Coster determines a suitable plate layout, all drop material (material remaining
DEFAULTS MENU
after a virgin plate has been cut) is reduced by the waste from flame cutting, and this
adjusted size is remembered so that it may be reused to fabricate other components.
Pipe Material Waste and Pipe Minimum Cut Length (for nozzles only) -- You can
specify a value for one or both of these entries. If you enter a zero for both of these items
no waste is considered.
When a nozzle is cut from a pipe material, a certain amount of material waste is
considered. This waste, expressed as a percentage, is added to the calculated nozzle
length if the nozzle length is greater than the minimum cut length. This length,
including waste, is used to determine the nozzle material cost in the Vessel Detail Cost
and pipe requirements in the Bill of Materials.
The waste may also be determined by the minimum length of nozzle used. If the nozzle
length calculated is less than the minimum cut length, then the length used to determine
the nozzle material cost in the Vessel Detail Cost and pipe requirements in the Bill of
Materials will be the minimum cut length.
Post Weld Heat Treatment (PWHT) -- Enter the cost per 100 lb for post weld heat
treatment. Coster determines that global PWHT is required if the following components
all require PWHT -- ASME B16.5/16.47 body flange, ASME Section VIII Division 1
Appendix 2 flange, 2:1 head, f&d head, hemi head, flat welded head, transition, cylinder.
Otherwise if PWHT is required on some but not all of these components then Coster
determines that local PWHT is required. If global PWHT is determined then Coster will
also add the weight of the saddles, skirt base ring and compression ring, legs (including
leg base plate and leg pad), skirts, and vacuum rings to the weight of the welded
components. If the ASME 16.5/16.47 body flange requires PWHT then the blind weight
will be added to the weight of the welded components. Similarly the weight of the pad
will be added if the nozzle to which it is attached requires PWHT. Global PWHT is
calculated using this cost per 100 lb according to the weight of the welded components.
If local PWHT is required you will be asked to enter a total cost for the vessel during the
estimating process.
Maximum Allowable Plate Length -- Enter the maximum plate length which will be
used when calculating the required plate size for transitions, conical skirts and skirt base
rings and also the plate length that may be entered as a user defined size. The default is
set to 480 inches.
Maximum Allowable Plate Width -- Enter the maximum plate width which will be
used when calculating the required plate size for transitions, conical skirts and skirt base
rings and also the plate width that may be entered as a user defined size. The default is
set to 120 inches.
Minimum Manway Diameter Required to Add Davits -- Enter the minimum
manway diameter which will determine whether davits will be added in this estimate.
The default is set to 16 inches. The "Always Add Davits" checkbox must also be
checked or davits will not be considered as part of the estimate.
DEFAULTS MENU
Cylinders -- Select the method which will be used to estimate cylinders -- Fabricated
in house, Purchased (formed/tacked only) or Purchased (formed/tacked/welded). The
default is set to "Fabricated in house".
Always Add Davits -- Check this box to add davits to manway openings greater than
or equal to the "Minimum Manway Diameter Required to Add Davits" value. If this box
is unchecked davits will not be considered. The default for this box is "checked".
Square All Sides of Plate -- Check this box to allow for squaring of each stock or userdefined plate. An allowance equal to the "Cut Width (waste from flame cutting)" will be
made before Coster selects a suitable plate size to fabricate each component. If this box
is "unchecked" then the exact dimensions of the stock or user-defined plate will be used
when determining the plate size for fabrication. The as-shipped default for this box is
"checked".
Labor Rates
Manufacturing Labor Rate -- Enter your shop's per hour labor rate ($/hr).
Wire Brush Labor Rate -- Enter the per hour labor rate to clean or blast an area using
the wire brush method.
Sandblasting Labor Rate -- Enter the per hour labor rate to clean or blast an area for
all types of sandblasting other than wire brush.
Primer Labor Rate -- The per hour shop charge to apply the primer.
Paint Labor Rate -- The per hour shop charge to apply the paint.
Welding Labor Rate -- Enter the currency per hour labor rate for welding. This labor
rate is used to calculate welding labor costs on all components.
Program Output
Active Cost Source Database -- Select another Coster database to use for estimating
from this dropdown box which contains a list of the database files (*.mdb files) located
in the selected directory. The default directory is the "Coster Defaults" directory. The
name of the new database selected (including the drive and directory) will be saved in
the Coster registry settings and Coster will use this new database for estimating until a
different database has been selected. This option provides an opportunity to estimate
vessels using the costs supplied from a variety of vendors. The database used for
estimating a vessel is printed on the second line of the estimate on the Vessel Detail Cost
sheet. Select the Database Name option from the Coster Main Menu to display the name
of the database currently being used for estimating.
Note: When you install a new version of Coster the database registry setting is reset to
CostDB.mdb. If you would like to use a database other than CostDB.mdb for estimating
DEFAULTS MENU
you will need to use this option to reselect your database each time you install a new
version of Coster.
Active Cost Source Drive / Active Cost Source Directory -- Select the drive and
directory where the new database file (*.mdb file) is located.
Note: The CostSS.xls file must exist in the same directory as the new database file
(*.mdb file) selected. If the CostSS.xls file is present then Coster will use the new
database file selected for estimating and will use the CostSS.xls file in this directory as
the template for estimating until a new database is selected in another directory. If the
CostSS.xls file is not present then Coster will display an error message and will revert
back to the previous database file for estimating.
Figure 7-4
Database Error Message
Print Expanded Form of Estimate -- The default for this box is "checked". The
estimate will be printed as shown on the screen which may take several pages to print. If
this box is "unchecked" Coster will condense the nozzle section of the estimate to fit all
the columns on one page when printing in landscape mode.
Display Cutting Sketch on Estimate -- The default for this box is "checked". Coster
includes a column to display the cutting sketch number on the Bill of Materials sheet and
the cutting sketch(es) used are displayed at the bottom of the Bill of Materials. This
provides the layout of each component fabricated from plate material. To reduce the size
of the spreadsheet file you may choose to eliminate these cutting sketches ("uncheck"
this box) from the estimate.
Design Program To Use -- The materials list used within Coster is read from the asme
and user defined databases from the Compress or Modeler program which Coster defines
as the "design program". The Modeler program is the "as-shipped" default design
program. The materials displayed from these databases are simplified using the short list
selected within the design program. On the database tables you may select one of the
materials listed in the drop down list or type in a material name. On the "revise alias
lists" dialog you may only select from the list of materials displayed. The materials list
used in Coster is updated after the design program is closed or when a material is added
to the user.mdb file using the "save this in the main database" option in the design
program.
DEFAULTS MENU
Tray Supports
Select the material, structural type, and size to use for estimating tray supports. Material cost is
based on the material, structural type, and size as specified on the "Structures/Rings/Tray Supports
Material Cost table".
Welding
Weld Detail
Figure 7-5
Weld Detail
Type of Welding -- Select V welding or U welding to weld components.

Single V <= thickness > Double V and Single U <= thickness > Double U -- The
number entered here specifies the thickness of the vessel where Coster automatically
switches from single to double welding for estimating. For example, if you have selected
a V type weld and enter 1 for thickness then vessels with thicknesses less than or equal to
1" will be welded with single V type welds and vessels with a thickness greater than 1"
will be welded with double V welds. To force all welding on a vessel to use double V
(double U), enter 0 for this input. To force single V (single U), enter a large number for
thickness.
Weld Gap (All Joints) -- Enter the weld gap between components. Refer to the icon
when you click on this item:
DEFAULTS MENU
Single V
Double V
Single U
Double U
Weld Straight Section -- Enter the length. Refer to the icon displayed.
Single V
Double V
Single U
Double U
Weld Bevel Angle -- Enter the bevel angle of the component when preparing for
welding. Refer to the icon displayed.
DEFAULTS MENU
Single V
Double V
Single U
Double U
Weld Recovery -- Enter the percentage of the welding rod that will actually be used
during welding. A value less than 100% will include weld wastage in your estimate.
Operator Weld Efficiency -- Enter the percentage of time actually spent welding by
the operator.
Bevel Angle (Nozzle Groove Welds) -- Enter the angle. Refer to the icon displayed.
This input is available only when V type welding is selected.
Single V
Double V
U Groove Weld Radius -- Enter the radius of the weld type chosen. Refer to the icon
displayed. This input is available only when U type welding is selected.
DEFAULTS MENU
Single U
Double U
Weld Reinforcement -- Click on the Weld Reinforcement button to retrieve the Weld
Reinforcement table which displays the height of the weld bead projecting beyond the
surface of the parts being welded.
Diameter/Longitudinal Weld Seams Ratio
Figure 7-6
Diameter/Long Weld Seams Ratio
Values entered on this dialog are considered for cylinders, fabricated nozzles, and
cylindrical skirts if the corresponding Use Custom Plates Cut To Component Size
checkbox has been selected. Pads and saddles are not affected by these selections.
Transitions, conical skirts, and skirt base rings do not use these values (see Custom Cut
Plates (Alternate Material Layout) on page 11-13).
DEFAULTS MENU
Diameter (in) <= -- Numbers entered in the left column indicate a diameter range.
These diameters must be entered in ascending order.
Number of Long Seams -- Numbers entered in the right column indicate how many
long seams are required for the diameter range specified in the left column. For
example, the number 152 displayed in the left column means that all diameters greater
than 114 inches but less than or equal to 152 inches will require 4 long seams.
Therefore, if a vessel component diameter is 120 inches, it will require 4 long seams.
The values initially displayed on the Ratio of Long Seams to Diameter dialog are
defaults supplied by Coster which may be edited. Revised values are saved in the
CostDB.mdb database. When the program is loaded, if all values on this dialog are input
as zero, Coster automatically reloads the orginal default values.
Use Custom Plates Cut to Component Size -- These checkboxes tell Coster to use
the actual dimensions of each component to calculate material costs for cylinders,
transitions, skirts, skirt base rings, and fabricated nozzles. No additional material cost
for drop is considered. The plate dimensions for each component are listed in the Bill of
Materials on the estimate. Because Coster is not determining plate sizes, the number of
long seams for cylinders, cylindrical skirts, and fabricated nozzles is not known. In
order to calculate the longitudinal weld length (length of the component multiplied by
the number of long seams), Coster reads the number of long seams for a particular vessel
diameter from the Diameter/Longitudinal Weld Seams Ratio dialog. The circumferential
weld length is calculated according to the circumferential seam length. The default for
the cylinder, transitions, skirts, and skirt base rings box is "unchecked". The default for
the fabricated nozzles box is "checked". Transitions, conical skirts, and skirt base rings
do not use these values to calculate longitudinal seam weld length (see Custom Cut
Plates (Alternate Material Layout) on page 11-13). Pads and saddles are not affected by
these checkboxes and are listed in the Bill of Materials as usual.
Fillet Welds
Vacuum Ring Intermittent Welding -- Enter the percentage of welding required to

attach the ring. For example, 100 means welded fully, whereas 60 means that 0.6 times
the total length is welded.
Vacuum Ring/Tray Supports Weld Deposition Rate -- Enter the rate at which weld
metal is deposited while welding vacuum rings/tray supports to the shell.
Vacuum Ring Fillet Weld Size -- Enter the vacuum ring fillet weld size which is used
to calculate the vacuum ring weld volume. The default is set to 0.25 inches.
Saddle Fillet Weld Size -- Enter the saddle fillet weld size used to calculate the weld
volume for the web plate, wear plate and each rib. The default is set to 0.25 inches.
Fillet Weld Size for Vessel Internals -- Enter the fillet weld size which is used to
calculate the tray weld volume. The default is set to 0.25 inches.
DEFAULTS MENU
Saddle Welding (1 side of seam) and Saddle Welding (2 sides of seam) -- Select the
number of sides to the weld the saddle. This option is used to calculate the weld length
and weld volume when costing saddles. The default is set to weld two sides.
Vacuum Ring Welding 1 Side and Vacuum Ring Welding 2 Sides -- Enter the
number of sides to weld the vacuum ring. This value is used to calculate the vacuum
ring weld volume. The default is set to weld two sides.
DEFAULTS MENU
COSTER SPREADSHEET
COSTER SPREADSHEET
General Spreadsheet Operation

Select Spreadsheet from the Coster main menu to display the Coster spreadsheet. This spreadsheet
operates as does Excel. Refer to your Excel manual for instructions. Formulas allow you to add,
subtract, multiply or divide the values appearing in various cells in the worksheet. To enter a
formula into a cell, begin by entering an equal (=) sign.
Regional Settings
The Coster spreadsheet estimate is compatible with regional settings in French, Italian, German,
Spanish, Dutch and Brazilian Portuguese.
Printing the Estimate
If the 'printer not found' message appears when you are trying to print from the spreadsheet open the
CostSS.xls template and select 'Print' from the File menu. When the 'printer not found' message
appears click 'ok'. Resave the CostSS.xls file and this should eliminate the message.
Printing the estimate as it is displayed on your screen may take several pages to print. To condense
the nozzle section of the estimate so that all columns will fit on one page when printing in landscape
mode (depending upon font size and column width) deselect the 'Print Expanded Form of Estimate'
checkbox from the Progam Output dialog of the Defaults - Other menu. Coster will automatically
condense the estimate for printing and then restore the estimate to the expanded form for display on
your computer screen.
Insert Miscellaneous Items

Coster provides this option to incorporate unique items that have not been included in the vessel
design into the Miscellaneous section of the estimate. Open a Coster estimate file by costing a
vessel or opening a previously saved estimate. Select Insert Miscellaneous Items from the
Spreadsheet Edit menu (this option will be "greyed out" on the menu until a Coster estimate is
displayed). A list is displayed showing items which have been saved on a unit cost and unit labor
basis in the Misc Items table(s) in the Coster database. A few examples of these items are vortex
breakers, mist extractors, and davits. Select one or more items from the list. (To select one item,
click on the item to highlight it. To select a group of items, highlight the first item in the group and
click on the last item in the group while holding down the Shift key. To select or deselect individual
items, highlight each item while holding down the Ctrl key.) The highlighted items will be added to
the Miscellaneous section of the estimate. Formulas are included for each item (making it easy to
revise quantities), and the addition of each item is reflected in the totals of the Miscellaneous section
and also in the final vessel totals. Formatting (fonts, colors) of the inserted miscellaneous items will
follow the formatting of the other items in the Miscellaneous section of the estimate in which these
items are added.
< COSTER SPREADSHEET 8 - 1 >
COSTER SPREADSHEET
These additional items are inserted on the last line of the Miscellaneous section of the
estimate. Coster automatically generates formulas in required cells for these items. To add
items automatically to each estimate generated add these items to the Misc Items Auto table
(see Misc Items Auto -- Coster includes a Misc Items Auto table that contains material
costs and labor hours for items to be included on every vessel estimated. Similar to the
Misc Items 1 table, the columns on this table must match those in the Miscellaneous section of the
Vessel Detail Cost sheet and must not be changed. More items may be added to this table, and you
may revise or delete the name plate record to suit your requirements. The difference between this
table and the Misc Items 1 table is that all items from the Misc Items Auto table will be added
automatically by Coster to the miscellaneous section of each estimate so that these items do not need
to be added manually each time. on page 6-5).
Included with Coster is a sample database table (Misc Items 1) which includes miscellaneous costs.
Note: The information in the fields of this table is the same as the information displayed
in the CostSS.xls template. When an item is inserted, Coster converts the units and
currency in the new row to match the units and currency on the estimate.
When adding items to the Misc Items table(s) enter pricing information for a quantity of one. The
formulas which are added to the cost estimate multiply this pricing information by the quantity. If
you always want to add more than one of these items to the estimate, you may wish to enter the
appropriate quantity in the quantity field of the Misc Items table(s). Otherwise if the quantity varies
for each vessel, enter a quantity of 1 in the Misc Items table(s) and change the quantity after you
have inserted the item into the estimate. You can create as many Misc Items tables as you wish
containing these specialized items. Create new tables by selecting the Add Miscellaneous Items
Table option from the Database File menu.
Customize the Template (CostSS.xls)

From the Spreadsheet menu, open the CostSS.xls spreadsheet template. To modify the appearance
(fonts, colors, underline, alignment, heading text, custom numbers, column width, justification) of
each subsequent estimate, revise the CostSS.xls file and save your changes. Any customizing made
to the CostSS.xls file becomes the default Coster setting. Each estimate will take on this new
appearance until further revisions are made.
The Coster estimate contains defined names (range names) for every numeric column. These
defined names describe the items listed in one column (excluding totals) from the first amount in the
column down to and including the underscore. The estimate also contains defined names assigned
to each column total as well as defined names to identify the first item of each section and the first
and last row and column of the headings for each section. The following figures show the defined
names that are part of the CostSS.xls template. In order for Coster to display the cost estimate
according to your customization on the CostSS.xls template, these defined names must not be
renamed and must reference the correct cell as listed in the table. If any of these names are missing,
a dialog box will display the missing names so that you may add them (see instructions below), but
Coster will continue to display the estimate using default headings and fonts.
There are three sheets in the CostSS.xls template:
COSTER SPREADSHEET
1)
Vessel Detail Cost (displays the cost estimate)
2)
Bill of Materials (displays the bill of materials, component weights, plate usage,
radiography table and cutting sketches)
3)
Summary (example of a customized summary).
To customize your estimate, revise the CostSS.xls template using the Coster spreadsheet or
Microsoft Excel version 7.0 and resave it. (Note: If you are using a newer version of Microsoft
Excel, the CostSS.xls template must be saved as a "Microsoft Excel 5.0/95 Workbook" for
compatibility with Coster). You may format cells any way you choose. For example, choose fonts,
text color, column widths, number of decimal places, or word wrap. The text in the headings of the
Shell, Nozzle and Miscellaneous sections of the Vessel Detail Cost sheet may also be revised with
the exception of the last row of the heading. The last row contains the units and currency and will be
displayed according to the units of the vessel file being costed and the currency selected within
Coster from the Currency/Exchange dialog. The formatting of each component (row) within a
section will follow the same formatting as the first row of that section from the spreadsheet template.
The titles, vessel name, date and time displayed at the top of each sheet may be formatted for fonts
and color, but the text is specified by Coster. Similarly the headings for the Bill of Materials, Plate
Usage and Radiography sections may also be formatted, but Coster will specify the text for these
sections. Any changes made to text on the spreadsheet template that is specified by Coster will be
overwritten on each estimate.
If you delete any of the defined names, you may add them from the Coster spreadsheet as follows:
1)
Select Spreadsheet from the Coster main menu (if you are not in the spreadsheet
already)
2)
Open the CostSS.xls template
3)
Move the cursor to the cell that you wish to name
4)
Select the Define Name option from the Spreadsheet Edit menu
5)
Type the defined name in the Name text box and click OK
COSTER SPREADSHEET
Figure 8-1
Define Name
There are other defined names provided on the CostSS.xls template to use as "hooks" for creating
your own customized summary. Coster creates these same defined names with each estimate. To
view the list of defined names, open the CostSS.xls template and select the Define Name option
from the Edit menu. As you scroll through the list of names, the formula in the box to the right will
display the corresponding sheet and cell that this name references.
COSTER SPREADSHEET
Figure 8-2 Vessel Detail Cost Sheet Defined Names
Figure 8-3
Bill of Materials Defined Names
COSTER SPREADSHEET
Figure 8-4
Summary Sheet Defined Names
Coster Tables
The tables included with Coster contain labor and material costs which may be used as provided or
edited as costs for labor and material change.
Note: Tables may be edited but not deleted or the program will not run. Tables must
always be resaved using the original "as-shipped" table name.
Most of the tables within Coster are indexed on the first field (column) but some tables are sorted
using the more than one field. For example, the weld neck flange costs table is sorted using the first,
second, third and fourth fields of the table. This primary index is used to sort the table as records
(rows) are added. The sorted table will be displayed after the table has been revised, closed and
reopened. Because of this indexing, duplicate entries are not allowed in the group of fields used for
sorting, and blank or empty cells in this group of fields will cause an error within Coster. The
interpolation feature requires that all values in this group of fields must be non-zero and all field
headings must be in ascending order.
The Material Properties table has fields for material, material density, welding rod
density, welding rod cost, normalization premium, impact testing, and metallurgy. These
fields must remain in the "as-shipped" order so that Coster can properly interpret the data.
The "as-shipped" database tables are saved in US currency and English units. Within Coster you
may change the units and currency of these tables so that the tables may be updated according to
your preferred units and currency. The units and currency selections will be "greyed out" on tables
that Coster will not allow these changes to be made.
Coster's Estimate Spreadsheet

A saved costed vessel file is referenced in this manual as an "estimate". The top line of the estimate
contains the following information:
-
Vessel Coster
COSTER SPREADSHEET
Filename of vessel being costed

Creation date and time
The estimate is in the same format as the CostSS.xls spreadsheet template.

The second line of the estimate displays the name of the database that was used to generate the
estimate.
Shell Section - The top section of the estimate includes the heads, cylinders, transitions, and skirts.
Nozzle Section - The middle section of the estimate includes the nozzles, couplings and flanges.
Miscellaneous Section - The bottom section of the estimate includes the skirt base rings,
attachments (packed beds, trays), studs, gaskets, weld rod, paint, primer, hydrotest, post weld heat
treatment, x-ray, and miscellaneous items.
Estimate Columns
As you read across a row in each section of the estimate you will find the following columns of
information.
Shell Section
1)
Item - the component identifier as specified in the vessel file.
2)
Material - the material as specified in the vessel file.
3)
Quantity - the number of items for this component.
4)
Finished Weight - the finished weight of the component. If identical components

are present, this is the total weight of the identical components as indicated by the
formula in the cell. The weight does not include material waste.
5)
Mat'l Cost - calculated based on the finished weight. If the component is
fabricated from plate material the equation in this cell displays the finished weight
times the material cost per lb. For heads and purchased cylinders the equation is
the unit cost of the component times the quantity.
6)
Surface Area - outside surface area of this component (heads, cylinders,
transitions and skirts).

7)
Long Seam Labor Hrs - welding labor hours.
a)
Heads, cylinders made from pipe material -- zero long seam labor hours.
b)
ASME B16.5/16.47 body flanges -- flange welding labor hours.
COSTER SPREADSHEET
c) Transitions, skirts, and cylinders made from plate material -- long seam
welding labor hours calculated according to the long seam weld volume using
welding rod density, long seam weld deposition rate, and operator weld
efficiency. If the cylinders are purchased formed and tacked only then the long
seam labor hours are calculated according to the long seam weld volume as above
similar to the 'Cut to Component Size' cylinders. If the cylinders are purchased
formed, tacked, and welded then long seam welding labor is zero.
d) Vacuum Rings -- welding labor hours calculated according to the ring weld
volume using welding rod density, ring weld depositon rate and operator weld
efficiency.
8)
Forming Labor Hrs
a) Cylinders made from pipe material, purchased cylinders, and ASME B16.5/
16.47 body flanges -- zero forming labor hours.
b) Transitions, skirts, and fabricated cylinders made from plate
material -- displays forming labor hours.
c) Vacuum rings -- displays forming labor hours from the Vacuum Ring Labor
table.
d) ASME B16.5/16.47 body flanges with blind attached -- displays blind labor
hours.
9)
Fitup Labor Hrs - fitup labor hours.
a)
ASME B16.5/16.47 body flanges -- flange fitting labor hours.
10)
Cutting Labor Hrs - cutting labor hours
11)
Layout Labor Hrs - layout labor hours
12)
Girth Seam Labor Hrs - girth seam welding labor hours.
a) Heads, cylinders, transitions, skirts -- girth seam welding labor hours

calculated according to the girth seam weld volume using welding rod density,
girth seam weld deposition rate, and operator weld efficiency.
b) Vacuum Rings -- welding labor hours calculated according to the ring to
shell weld volume using welding rod density, ring weld deposition rate, and
operator weld efficiency.
13)
Bevel Labor Hrs - labor hours to bevel heads, cylinders, transitions and skirts.
COSTER SPREADSHEET
14)
Blasting Labor Hrs - the hours required to blast the surface area specified above
for all types of blasting except wire brush.

15)
Cleaning Labor Hrs - the hours required to clean the surface area specified above
if wire brush is selected.

16)
Grind Labor Hrs - the hours required to prepare the seams for welding.
17)
Shell Labor Hrs - the total of long seam, forming, fitup, cutting, layout, girth
seam, blasting, cleaning, grind labor hours.
18)
Shell Labor Cost - the labor hours (long seam, forming, fitup, cutting, layout,
girth seam, blasting, cleaning, grind) multiplied by their respective $/hr rates (for
example, long seam and girth seam labor costs are calculated using the welding
labor rate, forming, fitup, cutting, and layout labor costs are calculated using the
manufacturing labor rate, blasting cost is calculated using the sandblasting labor
rate, cleaning cost is calculated using the wire brush labor rate, and grinding cost
is calculated using the manufacturing labor rate).
19)
Shell Mat'l Cost - the finished weight material cost calculated above.
20)
Shell Total Cost - Coster adds together the totals of Shell Labor Cost and Shell
Mat'l Cost above). This gives the total cost of the main components listed in the
top section of the worksheet.
Nozzle Section
1)
Item - the nozzle tag as specified in the vessel file and the identifier if different
from the nozzle tag.

2)
Material - the material of the nozzle as specified in the vessel file.
3)
Pad Material - material used for the pad as specified in the vessel file.
4)
Flange Type - the flange type is displayed in an abbreviated form as follows:
BLD - blind
BR - no flange (bare)
LJ - lap joint
LWNFB - full body long weld neck
LWNHB - heavy barrel long weld neck
LWNST - standard long weld neck
COSTER SPREADSHEET
LWNV1 - V1 variable body long weld neck

SO - slip on
SW - socket weld
TH - threaded
WN - weld neck
5)
Quantity - the number of items for this component.
6)
Nozzle Length - the finished length of the nozzle (waste not included).
7)
Nozzle Finished Weight - the finished weight of the nozzle. If identical nozzles
are present on the vessel, this is the total weight of the identical nozzles (waste not
included).
8)
Pad Finished Weight - the finished weight of the pad. If identical nozzles are
present on the vessel, this is the total weight of the pad from these identical
nozzles (waste not included).
9)
Flange Weight - the weight of the flange. If identical nozzles are present on the
vessel, this is the total weight of the flanges on these identical nozzles (waste not
included).
10)
Blind Weight - the weight of the blind flange. If identical nozzles are present on
the vessel, this is the total weight of the blind flanges on these identical nozzles
(waste not included).
11)
Nozzle Finished Weight Mat'l Cost - fabricated nozzle material cost is calculated
based on the finished weight of the specified material for this nozzle. The
equation displays the finished weight times the material cost per lb. Material cost
for nozzles made from pipe material is calculated using the nozzle length times
the pipe cost per ft. This pipe nozzle length is calculated according to the Pipe
Material Waste or Pipe Minimum Cut Length as entered on the Other Defaults
dialog. For appendix 2 flanges the material cost is calculated based on the
finished weight of the flange times the material cost per lb.
12)
Pad Finished Weight Mat'l Cost - pad material cost is calculated based on the
finished weight of the specified material for this pad. The equation displays the
finished weight times the material cost per lb.
COSTER SPREADSHEET
13)
Flange Cost - the cost of the flange.
14)
Blind Cost - the cost of the blind flange.
15)
Nozzle Installation Labor Hrs - the labor hours required to attach the nozzle to the
vessel (layout, fitup).

16)
Pad Installation Labor Hrs - the labor hours required to attach the pad to the
nozzle (layout, fitup).

17)
Flange Fitup Labor Hrs - the labor hours required to attach the flange. For
appendix 2 flanges the machining and drilling labor are included as part of the
equation.
18)
Blind Labor Hrs - the labor hours required to attach a blind flange.
19)
Forming Labor Hrs - the labor hours required to form the nozzle (fabricated
nozzles).
20)
Nozzle Cutting Labor Hrs - the labor hours required to cut out the hole for the
nozzle. For fabricated nozzles the labor hours to cut out the nozzle from plate
material is also included and for nozzles made from pipe material the labor hours
to cut the required length of pipe is also included.
21)
Pad Cutting Labor Hrs - the labor hours required to cut out the pad from plate
material.
22)
Nozzle Welding Labor Hrs - the labor hours required to weld the nozzle to the
component.
23)
Pad Welding Labor Hrs - the labor hours required to weld the pad to the nozzle.
24)
Long Seam Welding Labor Hrs - the labor hours required to weld the long seam
for fabricated nozzles calculated according to the long seam weld volume using
welding rod density, long seam weld deposition rate, and operator weld
efficiency.
25)
Flange Welding Labor Hrs - the labor hours required to weld the flange. Flange
welding labor is zero for long weld necks and studded outlet.
26)
Nozzle Labor Hrs - the total of all labor hours above (nozzle installation, pad
installation, flange fitup, blind, forming, nozzle cutting, pad cutting, nozzle
welding, pad welding, long seam welding, and flange welding labor).
27)
Nozzle Labor Cost - the individual itemized cost of labor for the total number of
labor hours shown in Nozzle Labor Hrs above (use welding labor rate to calculate
welding labor cost and manufacturing labor rate for all other labor costs).
COSTER SPREADSHEET
28)
Nozzle Mat'l Cost - the total of all material costs above (nozzle finished weight
mat'l cost, pad finished weight mat'l cost, flange cost, and blind cost).
29)
Nozzle Total Cost - Coster adds together the totals calculated for Nozzle Labor
Cost and Nozzle Mat'l Cost. This gives the total cost of all items listed in the
nozzle (center) section of the worksheet.
Miscellaneous Section
Hydrotest hours are reported in this section. If the blind flange is not part of the vessel
design, hydrotest hours for the flange are calculated as the labor hours to attach and
remove a blind flange. Otherwise, if all blind flanges are part of the vessel design, flange
hydrotest hours are zero. Hydrotest hours for the vessel are calculated using the formula
discussed earlier. Items that are included in the Misc Items Auto database table are
automatically included in the miscellaneous section of the estimate. Each cell contains a
formula when it is added to the estimate. The equation is the value from the Misc Items
Auto table times the quantity cell.
1)
Item - the attachment identifier as specified in the vessel file.
2)
Material - of the attachment specified in the vessel file.
3)
Quantity - the number of items for identical attachments.
4)
Finished Weight - the finished weight of the attachment. If identical attachments

are present, this is the total weight of the identical attachments. If "global" post
weld heat treatment (PWHT) is required then the weight of the welded
components is displayed in this column.
5)
Finished Weight Mat'l Cost - of the specified material cost for this attachment. If
a value for x-ray has been entered then this column contains the total x-ray cost.
For skirt base rings the material cost is calculated based on the finished weight.
The equation in this cell for skirt base rings displays the finished weight times the
material cost per lb. If post weld heat treatment (PWHT) is required then the
value entered will be displayed in this column. If "global" PWHT is entered as a
cost per 100 lb value then an equation of weight of the welded components times
the cost per 100 lb is displayed. If "global" PWHT is entered as a total cost then
the value entered is displayed in this column. "Local" PWHT is always entered as
a total cost which is displayed in this column.
6)
Consumables Cost - totals for welding rod cost and cost of lining and insulation
clips are displayed in this column.

7)
Fitup Labor Hrs - fitup labor for insulation, lining, saddles, legs, legs base plate,
and legs pad.

a)
Insulation, lining -- labor hours per clip.
COSTER SPREADSHEET
b) Saddles -- the equation displayed in this cell is saddle fitting labor hours +
wear plate fitting labor hours.
8)
Cutting Labor Hrs - cutting labor for saddles, skirt base rings, and compression
rings.
a) Saddles -- the equation displayed in this cell is rib cutting labor hours + wear
plate cutting labor hours + web plate cutting labor hours + base plate cutting labor
hours.
9)
Layout Labor Hrs - layout labor for legs, legs base plate, legs pad, skirt base
rings, and compression rings.

10)
Welding Labor Hrs - welding labor for saddles, skirt base rings, compression
rings, legs, legs pad, and tray supports.

a) Saddles -- the equation displayed in this cell is rib plate welding labor hours
+ wear plate welding labor hours + web plate welding labor hours
b) Skirt Base Ring and Compression Ring -- equation displays the total of
groove welding labor hours + fillet welding labor hours + gusset welding labor
hours
c) Legs -- equation displays the total of legs to shell or pad welding hours + legs
to base plate welding hours.
11)
Drilling Labor Hrs - drilling labor for bolts in legs base plate, skirt base ring, and
compression ring.
12)
Installation or Other Labor Hrs - installation or other labor hours for platforms,
railings, ladders, insulation, lining, davits, installing tray supports, paint, primer,
hydrotest, skirt base rings, and compression rings.
a) Skirt Base Ring and Compression Ring -- the hours required to blast/clean
the surface area plus the hours required to prepare the seams for welding. The
equation in this cell displays the total of blasting labor hours + cleaning labor
hours + grinding labor hours (cleaning labor hours are calculated if wire brush is
selected and blasting hours are calculated for all other types of blasting/cleaning).
13)
Misc Labor Hrs - the total of all labor hours above (fitup, cutting, layout, welding,
drilling, and installation/other)

14)
Misc Labor Cost - the cost of labor for the total number of labor hours shown in
Misc Labor Hrs above. Welding labor hours are calculated using the welding
labor rate, paint labor hours are calculated using the paint labor rate, primer labor
hours are calculated using the primer labor rate, blasting labor hours are
calculated using the sandblasting labor rate, cleaning hours are calculated using
COSTER SPREADSHEET
the wire brush labor rate, and all other labor hours are calculated using the
manufacturing labor rate.
15)
Misc Mat'l Cost - the combined cost of the Finished Weight Mat'l Cost and
Consumables Cost columns above.

16)
Misc Total Cost - Coster adds together the totals calculated for Misc Labor Cost
and Misc Mat'l Cost. This gives the total cost of all items listed in the
miscellaneous (bottom) section of the worksheet.
X-Ray Cost
The last row on the estimate displays the x-ray cost in the Finished Weight Mat'l Cost column for
the vessel if a positive amount is entered.
Vessel Total Costs

Total Finished Vessel Weight
Coster displays the sum of the total weights (lb) on the estimate -- Shell Total Weight (ShTotWt) +
Nozzle Total Weight (NozTotWt) + Pad Total Weight (PadTotWt) + Flange Total Weight
(FlangeTotWt) + Blind Total Weight (BlindTotWt) + skirt base ring weight + saddles weight + davit
weight + legs weight -- as the Total Finished Vessel Weight. The skirt base ring, saddles, davits, and
legs weight are displayed by individual cell reference.
Finished Vessel Cost
Coster calculates the average $/lb cost of the total vessel based on the Total Vessel Cost divided by
the Total Finished Vessel Weight.
Total Plate Material Cost
The Total Plate Material Cost is the sum of the Stock Material Cost and User Defined Material Cost
from the Bill of Materials plate usage section (TotalStockMatlCost + TotalUserDefinedMatlCost).
Finished Weight Plate Material Cost
This is the sum of all material costs made from plate (cylinders -- excluding purchased cylinders,
skirts, transitions, fabricated nozzles, pads, skirt base rings, saddles).
Unused Plate Material Cost
Coster calculates the unused plate material cost by taking the total (purchased) plate material cost
and subtracting the cost of the finished weight of plate components.
COSTER SPREADSHEET
Total Costs for the Vessel
Coster calculates three subtotals for labor hours in the Shell Labor Hrs, Nozzle Labor Hrs, and Misc
Labor Hrs columns. These three subtotals are added together to give the total labor hours for the
vessel. This total is reported as TOTAL VESSEL LABOR HOURS.
Similarly, Coster calculates three subtotals for labor cost in the Shell Labor Cost, Nozzle Labor
Cost, and Misc Labor Cost columns. These three subtotals are added together to give the total labor
cost for the vessel. This total is reported as TOTAL VESSEL LABOR COST.
Coster calculates three subtotals for material cost in the Shell Mat'l Cost, Nozzle Mat'l Cost, and
Misc Mat'l Cost columns. The sum of these three subtotals plus the unused plate material cost give
the total material cost for the vessel. This total is reported as TOTAL VESSEL MATERIAL COST.
TOTAL VESSEL LABOR COST is then combined with TOTAL VESSEL MATERIAL COST to
show the final TOTAL VESSEL COST.
Bill of Materials
A bill of materials is displayed on sheet 2 of the estimate. This lists the quantities and descriptions of
materials required to build the vessel.
1)
Quantity - the actual component quantity required. If the component is made
from pipe material, this quantity is the length of pipe required.

This length of pipe includes the Pipe Material Waste or Pipe Minimum Cut Length as
shown on the Other Defaults dialog. In cases where pipe material is the same for more
than one nozzle, these lengths (including waste), will be added together for a combined
pipe length.
2)
Material - the material specification as found in the vessel file.
3)
Component - the identifier as found in the vessel file. If the component is a
nozzle, the nozzle tag name is displayed. If the component is a flange, the type of
flange is displayed.
4)
Description - the actual dimensions of the component.
5)
Section Qty - how many sections (pieces) are required to assemble the
component.
6)
Dimensions of Sections Req'd to Assemble Component - the size of each of the
sections required to assemble the component from plate material. In the case of
purchased cylinders this column contains the type of purchased cylinder (either
formed and tacked or formed, tacked, and welded)
COSTER SPREADSHEET
Note: Coster calculates the rectangular plate size required to cut out the pad and
assumes that the pad will be cut from a piece of scrap material. Therefore the plate
quantity, size of plate required to cut each section and drop columns are left blank.
7)
Plate Qty - how many pieces of plate material are required to cut the sections
shown in 6 above.
8)
Size of Plate Required to Cut Each Section - the plate size required to cut the
section of the dimension shown in 6 above. The plate sizes shown in this column
are stock plate sizes found on the Stock Plate Sizes tables (English or Metric),
user defined plate sizes that you have entered while costing the vessel, or drop
plates left over after cutting out a previous component.
The following list is displayed beneath the Size of Plate Required to Cut Each Section
column heading:
U(cut from user defined plate, no stock)
G(girth seams added to plate layout)
The letter U is shown in the column to the left of the plate size listed if Coster could not
find a suitable plate size in stock (from the Stock Plate Sizes table) and you entered a
plate size for this component. The letter G means that additional girth seams were
required to fabricate this component from the available plate sizes. The letters G U mean
more girth seams were added and a user defined plate size was used for this component.
9)
Weight of Source Material - this column displays the component weight
10)
Cutting Sketch - this column displays the number of the cutting sketch used to cut
out this component. The cutting sketches used are displayed at the bottom of the
Bill of Materials sheet to show the layout used for cutting.
11)
Drop From - sometimes it is possible to cut smaller component sections from

leftover pieces of plate material. This column displays the identifier of the
component that contributed the plate remnant.
COSTER SPREADSHEET
Plate Usage (Bill of Materials)

Stock Plates Required
This is a list of the actual plates which must be purchased to fabricate the vessel, along with material
cost for each plate. These stock plates were used by Coster because the sizes were available in the
Stock Plates Sizes tables.
User Defined Plates Required
This is a list of the user specified plates sizes which must be purchased to fabricate the vessel but
could not be found in the Stock Plate Sizes tables. In this instance Coster prompts the user to
provide a suitable plate description. There is also a material cost for each plate.
Drop Material Used
This is a list of the drop material used to fabricate various components. Drop is the material that
remains that can be reused after cutting a virgin stock plate.
Drop Material Remaining
This is a list of the drop material that Coster could not reuse for this vessel, along with a
corresponding material cost for each piece. Coster assumes that the drop material is always a
rectangular piece of plate.
Scrap Material
This is a list of the material that is left over that Coster cannot use because of its odd geometry, along
with a corresponding material cost for each piece of scrap. One example of scrap is the material
remaining after a multiple segment base ring has been flame cut.
Total Unused Material Cost
This cost is calculated as the drop plates remaining material cost plus the scrap material cost.
Radiography
A table is displayed below the Bill of Materials indicating the weld type and length of weld for each
type of radiography (full, spot, no radiography). This same table is displayed on the x-ray dialog to
use as a guide for entering the x-ray cost.
COSTER SPREADSHEET
Summary (Create a Customized Report)

The third sheet of the estimate is a summary report. The summary can be modified to suit your
preferences. At the top of the spreadsheet on the left, the active cell is displayed, along with the
formula bar showing the contents of that cell. The corresponding cell in the spreadsheet displays the
result of this formula bar. As you move through the cells in the summary you will notice that the
formula bar does not always contain a specific number. It sometimes contains a defined name from
the Vessel Detail Cost sheet. By using these defined names you can create your summary to
automatically link values from the Vessel Detail Cost sheet. Formulas may be added to your
summary in order to total various costs or add profit margins.
Note: Remember that this customization must be saved on the CostSS.xls spreadsheet
template as this is the file Coster uses to generate each estimate.
DATABASE TREE MENU
DATABASE TREE MENU
The database tree menu displays the operations required to estimate each component. Through this
tree you can access each database table and the default dialogs associated with each operation.
Operations common to many components are listed together under the "Common Operations"
heading of the database tree. The database tables and default dialogs associated with these common
operations may be accessed through these branches of the database tree. Although the common
operations are also listed with each individual component these common operations are marked with
an asterisk (*) because the database tables and default dialogs cannot be accessed from this branch
of the tree.
< DATABASE TREE MENU 9 - 1 >
DATABASE TREE MENU
< DATABASE TREE MENU 9 - 2 >
HELP MENU
10
HELP MENU
The help menu displays information about the Coster program.
Figure 10-1
Help Menu
About Coster
This option displays the Coster version and copyright information.
Coster Directories
This displays a list of the directories where the Coster files are located as specified during
installation of the program.
Database Name
Selecting this option will display the directory and name of the database that is currently being used
for estimating vessels. This database name also appears at the top of each spreadsheet estimate.
< HELP MENU 10 - 1 >
HELP MENU
< HELP MENU 10 - 2 >
CALCULATIONS DESCRIPTION
11
General Calculations For All Components

The currency and units used to display the estimate are based on the units of the vessel file being
costed and the Report Currency selection from the Currency/Exchange dialog of the Defaults menu.
The weld recovery and operator weld efficiency are read from the values entered on the Welding
Detail dialog on the Defaults - Welding menu. The manufacturing labor rate and welding labor rate
are read from the values entered on the Labor Rates dialog on the Defaults - Other menu. The weld
recovery and operator weld efficiency are divided by 100 for use in the calculations below.
Unless otherwise specified, units used in the following calculations are:
angle
bevel angle
blast/clean coverage
corrosion
cut width
density (bed, lining, insulation)
diameter
elevation
grinding rate
head cost
height
hydrotest equation values
impact testing
insulation/lining clip labor
insulation/lining clips cost
insulation/lining coverage
length
manufacturing labor rate
material density
nominal size
normalization
nozzle inside projection
operator weld efficiency
paint/primer application labor
paint/primer coverage
degrees
degrees
gal/100 sq ft
in
in
lb/cubic ft
in
in
hrs/ft
$/each
in
ft
%
hrs/clip
$/clip
sq ft/clip
in
$/hr
lb/cubic in
in
%
in
%
hrs/100 sq ft
gal/100 sq ft
pipe cost
pipe material waste
pipe minimum cut length
plate cost
saddle fillet weld size
saddle height
saddle welding 1 or 2 sides
straight flange
surface area
thickness
vacuum ring fillet weld size
vacuum ring intermittent welding
vacuum ring weld deposition rate
vacuum ring welding 1 or 2 sides
volume
weight
weld deposition rate
weld gap
weld recovery
weld size
welding labor rate
weld rod density
width
x-ray weld length
$/ft
%
ft
$/100 lb
in
in
in
square feet
in
in
%
lb/hr
cubic in
lb
lb/hr
in
%
in
$/hr
lb/cubic in
in
ft
Outer diameter is usually read from the .xml file. Otherwise outer diameter is calculated as:
OD = ID + 2 * thickness.
Longitudinal and circumferential weld cross section areas and weld lengths are calculated by Coster
according to the weld type specified based on diameter and thickness -- use OD for cylinders,
Left ID for transitions and skirts, OD for nozzles, and ID for heads. The deposition rates required to
< CALCULATIONS DESCRIPTION 11 - 1 >
weld these seams are read from the Weld Deposition Rate - Longitudinal Seam Weld and Weld
Deposition Rate - Circumferential Seam Weld tables based on thickness and metallurgy.
The lining weight and insulation weight are provided by the COMPRESS .xml file for cylinders,
transitions, heads, and skirts.
Interpolation Method Used by Coster

Coster interpolates values within one field (column) if each field belongs to a separate group as on
the Miscellaneous Fabrication Labor table (fields contain data for cutting, fillet welding, groove
welding, drilling hours, and bevelling labor) or within one record (row) if each record belongs to a
separate group as on the Plate Costs table (records contain data for different materials). We refer to
this as "single interpolation".
Coster can also interpolate between fields and records if all the information contained on a table is
related as on the Cylinder Forming Labor table (fields contain cylinder ID and records contain
cylinder thickness). We refer to this as "multiple interpolation".
To interpolate values, the records and field headings must be in ascending order as shown in the
following examples.
Single Interpolation
Coster interpolates to find a value between two non-zero coordinates in one field or record. In this
example Coster finds a value for weld deposition rate at a thickness of 2.75". Coster searches for the
first non-zero value in the deposition rate column above and below the 2.75" thickness. In our
example, the first non-zero value above 2.75" is 1.6 (at 1" thickness), and the first non-zero value
below 2.75" is 7.4 (at 4.5" thickness). Once these two points have been located, Coster calculates
the weld deposition rate at 2.75" to be 4.5 1bs/hr as follows:
( 7.4 1.6 ) ( 4.5 1 ) ( 2.75 1 ) + 1.6 = 4.5
Thickness
1
1.75
2.5
2.75
3.25
4
4.5
Deposition Rate
1.6
?
7.4
Multiple Interpolation
Coster uses multiple interpolation to determine an intermediate value between four non-zero values
arranged in a "four-cornered" pattern. Suppose the following data were available. The following
steps show how Coster determines the labor hours required to weld a 6" diameter nozzle with a
0.875" weld thickness:
weld legsize
0.25
0.375
0.5
0.75
0.875
1
1.25
1.5
2
2.5
3
1)
1
6
12
2
6.2
13
4
6.5
8
7
8.205
? 8.818
14
15
16
7.5
48
8
20
30
In the first interpolation, Coster determines a value for labor hours for 4" diameter
and 0.875" thickness calculated as follows.
( 14 6.5 ) ( 3 0.25 ) ( 0.875 0.25 ) + 6.5 = 8.205

2)
The second interpolation reveals a value for labor hours for 8" diameter and
0.875" thickness as follows.
( 15 7 ) ( 3 0.25 ) ( 0.875 0.25 ) + 7 = 8.818

3)
Coster now takes the values determined in Step 1 and Step 2 above, interpolates
between these two points to determine the labor hours for 6" diameter and 0.875"
thickness as follows.
( 8.818 8.205 ) ( 8 4 ) ( 6 4 ) + 8.205 = 8.512

Therefore the (interpolated) labor hours required to weld a 6" diameter nozzle with a 0.875" weld
thickness is 8.512 hours.
How Coster Determines Material Layout and Plate Requirements (Default Method)
All stock plate sizes listed in the Coster database are assumed to be available in unlimited quantities
during the fabrication process. Stock plates are simply plates of standard size that are readily
available for purchase. You can change the plate sizes available to Coster by selecting Stock Plate
Sizes from the Material menu. Coster decides where to place the vessel weld seams and which
stock plate sizes to specify based on what may be thought of as a two stage process.
Stage (1) - The locations of the girth seams are specified by the user based on the
cylinder lengths entered in COMPRESS. The only time Coster will add girth seams is
when the user has specified a cylinder length longer than can be made from the longest
stock plate. Coster strives to minimize the number of longitudinal seams by selecting
stock plate sizes that do not need to be pieced together even if this results in more scrap
material. The layout of conical transitions, conical skirts and skirt base rings is more
complicated and is described in detail in a later section.
Stage (2) - Stage (1) establishes the required length and width of each plate required to
fabricate the vessel. This "required plate size" is the size that once rolled forms the
required cylinder diameter. For large diameters more than one plate may be required to
form each component. The stock plate used to cut out the required plate is determined
by comparing the required plate size to all available stock plate sizes and then selecting
the stock plate (and layout) that leaves the most remaining material or "drop". If the
required plate can be cut entirely from a stock plate size then the best of cutting sketches
1 through 4 is selected. If none of the stock plates is large enough then the better of
cutting sketches 5 or 6 will be used (see Cutting Sketches on page 11-9). If the "use
squared plates" checkbox from the Fabrication dialog on the Defaults - Other menu has
been "checked" (this is the "as-shipped" default) then the sides of each required plate
chosen for fabrication must allow for squaring of the plate -- in other words an allowance
of the "Cut Width (waste from flame cutting)" from the Fabrication dialog on the
Defaults - Other menu is made. For example, if the "Cut Width (waste from flame
cutting)" is equal to 0.5" then to determine if a plate which has a width of 96" can be
used to fabricate a component Coster will compare the required size to the plate width
(96") minus a cutting allowance on both sides of the plate (0.5" x 2) or a 95" plate width.
Note that the specified flame cutting allowance is deducted from the drop piece size
(based on the selected layout) before it is placed in the drop inventory if the "use squared
plates" checkbox on the Fabrication dialog of the Defaults - Other menu is "unchecked".
Depending upon the layout used for cutting (cutting sketch), the side(s) of the drop piece
may have already been squared so this allowance is not necessary when comparing the
dimensions of the drop piece to the required plate size. The flame cutting allowance will
only be considered for sides that are "not squared" when the "use squared plates" option
is "checked". Refer to the Cutting Sketches With Drop Dimensions (includes
allowance for squaring of plate) on page 11-10 that show the dimensions of the drop
pieces after allowance is made for squaring of the plate.
As stage (2) proceeds Coster accumulates all drop material in a "drop inventory". Before selecting a
"virgin" stock plate Coster first examines the drop inventory to see if the required plate size can be
cut from an existing piece of drop material. In an attempt to maximize the use of drop material
Coster sorts the components in the vessel in the following order: cylinder, transition, skirt, and
nozzle in order to select stock plates for larger components first. A consequence of this arrangement
is that only drop from this vessel is available for use. The plate selection process can be summarized
as follows:
a)
Sort all of the vessel components in the following order: cylinder, transition,
skirt, and nozzle.
b)
First see if the required plate can be cut from an existing piece of drop. In an
effort to use the most drop possible Coster will use drop if it is as good as or better
than the required metallurgy. For example if the only difference between the
required plate and a drop piece is that the drop is normalized and the required
plate is not normalized then Coster will use the drop. If the required plate can be
made from drop skip step c).
c)
Find the stock plate size that produces the least amount (area) of drop. To do this
examine all available stock plate sizes trying cutting sketches 1 through 4. The
"best" stock plate size and cutting sketch are now known. If none of the stock
plates is large enough then try cutting sketches 5 and 6.
d)
Cut the required plate size from the "best" stock plate size and add the drop pieces
to the drop inventory. Note that the specified flame cutting allowance is deducted
from the drop piece size (based on the selected layout) before it is placed in the
drop inventory if the "use squared plates" checkbox on the Fabrication dialog of
the Defaults - Other menu is "unchecked". If the "use squared plates" checkbox
has been "checked" then the sides of each required plate chosen for fabrication
must allow for squaring of the plate using the "Cut Width (waste from flame
cutting)" from the Fabrication dialog on the Defaults - Other menu (see Cutting
Sketches With Drop Dimensions (includes allowance for squaring of plate) on
page 11-10). These sketches also show which sides of the drop pieces are
considered to be "squared". Note also that the drop material takes on the
characteristics of the plate from which it was cut. For example if a piece of drop
is cut from normalized stock then it too is marked as normalized.
e)
Repeat the process using the next required plate size (starting at step b) until all of
the required pieces have been cut.
The material which is added to the drop inventory for possible use in fabricating another component
is assumed to be rectangular in shape. Other shapes are considered unusable and are referred to as
scrap material. Examples of "scrap" are the irregular shapes remaining after cutting out pads,
transitions, conical skirts, and skirt base rings. A list of the stock plate sizes, user defined plate
sizes, drop material and scrap are listed on the Bill of Materials sheet on the estimate (see Stock
Plates Required on page 8-17).
When piecing together a component, assuming that the "use squared plates" checkbox is "checked"
and the "Cut Width (waste from flame cutting)" is equal to 0.5", Coster selects a plate layout that
will minimize the number of long seams and will not allow a plate width of less than the Minimum
Shell Course Length specified on the Defaults - Other dialog. For example, Coster may choose to
fabricate a component, 61" ID (midcircumference 193.208"), 119" length, 0.5" thickness using three
sections. If two full plates (96" x 120" -- actually 95" x 119" after allowing for the waste from flame
cutting) are used for the first two sections then the last plate section (3.208" x 119") would be less
than the minimum shell course length (12"). Instead Coster would fabricate this component in three
sections as follows (the last two sections would be divided equally) -- one section 95" x 119" and
two sections 49.104" x 119". To test this, create a carbon steel cylinder 61" ID x 119" length x 0.5"
thickness and save it. Open the Stock Plate Sizes (English units) table. For each plate size in the
0.5" thickness record type SS in the cell with the exception of 96" x 120" (type CS in this cell). This
forces Coster to fabricate this cylinder from the 96" x 120" plate size since this size is the only
available carbon steel material in 0.5" thickness. Set the "Minimum Shell Course Length" and the
"Cut Width (waste from flame cutting)" on the Fabrication dialog of the Defaults - Other menu to
12" and 0.5" respectively. Close the database and cost the vessel. The plate sizes listed on the Bill
of Materials will be the same as shown above. After testing replace the previous metallurgies in the
0.5" thickness record on the Stock Plate Sizes (English units) table.
How Coster Determines The Layout of Conical Sections

Coster minimizes the welding required to fabricate transitions and conical skirts by specifying that
the cone be made using the fewest possible number of segments. This is accomplished by taking
the cone geometry and determining what plate size would be required to fabricate it from one
segment. If there is a stock plate size large enough then this is considered to be the "best" layout.
Otherwise the number of cone segments is increased until the minimum number of segments that
can be accommodated by the stock plates is found. Once the "best" required plate size has been
determined the stock plate size is selected per the procedure described in Stage (2) above. If more
than 12 segments are required Coster will split this cone into two separate cones of equal axial
length by adding a girth seam. The following equations are used to determine the size of the cone
segments:
Cone surface length, H =
L ------ 2
R = D L H ( DL DS )
Radians = ( D L D S ) H
For <= :
D S 2
- + (axial length) 2
------2
Required plate length, L = 2 R sin ( 2 )
Required plate width, w = R ( R H ) cos ( 2 )

For > :
Required plate length, L = 2 R
Required plate width, w = R ( 1 + cos ( ( 2 ) 2 ) )

where
DL = average cone diameter at the large end
DS = average cone diameter at the small end

Axial Length = cone axial length
longitudinal seam weld length = cone surface length, H

2
2
area of cone = ( R ( R H ) ) --2
scrap area = L w area of cone

The circumferential seam weld length is calculated according to the orientation of the
transition.
If the orientation of the transition from top to bottom is Small to Large calculate the
circumferential seam weld length using the Large OD attached to the next component:
DL
circumferential seam weld length = -----------------------------------------------number of segments
If the orientation of the transition from top to bottom is Large to Small calculate the
circumferential seam weld length using the Small OD attached to the next component :
DS
circumferential seam weld length = ----------------------------------------------number of segments
The cutting length is calculated as the circumferential seam weld length plus the
longitudinal seam weld length plus the length of the top end of the transition:
If the orientation of the transition from top to bottom is Small to Large calculate the top
end cutting length using the Small OD:
DS
top end cutting length = -----------------------------------------------number of segments
If the orientation of the transition from top to bottom is Large to Small calculate the top
end cutting length using the Large OD:
DL
top end cutting length = ----------------------------------------------number of segments
If there is only one segment then an extra cutting length of cone surface length, H, is
added because this length would be included only once in the longitudinal seam weld
length.
extra cutting length = cone surface length, H

If there is more than one segment then for each segment an extra cutting length of the
axial length is added
extra cutting length = axial length number of segments

The total cutting length is calculated:
cutting length= circumferential seam weld length

+ longitudinal seam weld length + top end cutting length + extra cutting length
How Coster Determines The Layout of Skirt Base Rings
For each base ring Coster estimates the total cost of labor and material needed to fabricate the base
ring by attempting to use from one to 6 segments. Of these six arrangements Coster chooses the
most economical layout. Depending on the size of the base ring and the available stock plate sizes
some layouts may not be physically possible and so may not be considered. The equations used to
layout the required base ring are described in Two Segments to Six Segments on page 11-61.
Cutting Sketches
Following are the cutting sketches which will be used to cut out each required plate size, where
plate width = width of the stock plate
plate length = length of the stock plate
x and y = dimensions of the required plate size
drop = rectangular plates added to drop inventory
A list of the sizes of each section used for fabrication is found on the Bill of Materials under the
heading Dimensions of Sections Req'd to Assemble Component. A list of the plate sizes used to cut
out each section is found on the Bill of Materials under the heading Size of Plate Required to Cut
Each Section.
Cutting Sketches With Drop Dimensions (includes allowance for squaring of plate)
The following cutting sketches indicate the dimensions of the drop pieces after allowance is made
for squaring of the plate.
Custom Cut Plates (Alternate Material Layout)

To bypass Coster's usual method of determining plate requirements as discussed on page 11-3 ff,
check the Use Custom Plates Cut to Component Size checkbox on the Diameter/Longitudinal Weld
Seams Ratio dialog from the Defaults - Welding menu.
When the Use Custom Plates Cut to Component Size checkbox is selected, Coster uses the actual
dimensions of each vessel component to calculate labor and material costs. Using this method
eliminates the "drop" from being included in the material cost. This option is available for cylinders,
transitions, skirts, skirt base rings, and fabricated nozzles. The "as-shipped" default for cylinders,
transitions, skirts and skirt base rings is "unchecked". The "as-shipped" default for fabricated
nozzles is "checked". The dimensions are listed in the Bill of Materials as user defined plate sizes.
Fabricated Cylinders, Cylindrical Skirts and Fabricated Nozzles
For these custom plate components, the circumferential seam weld length is calculated as the girth
seam weld length, and the longitudinal seam weld length is calculated according to the length of the
component multiplied by the number of seams (based on diameter) from the Diameter/Longitudinal
Weld Seams Ratio dialog on the Defaults - Welding menu. Cutting labor is not included for these
components because Coster uses a plate size of the exact dimensions required to fabricate the
component.
During costing, the number of long seams required for a particular diameter is looked up by Coster
from the Diameter/Longitudinal Weld Seams Ratio dialog. If the number of long seams returned
from this look-up is zero, the following dialog appears. A zero value will be returned if the actual
value in the table is zero or the component diameter is larger or smaller than the largest or smallest
diameter found on the Diameter/Longitudinal Weld Seams Ratio dialog.
Figure 11-1
Long Seams Required
Enter the appropriate number of long seams to correspond with the diameter shown in the left
column and click OK. Coster proceeds to calculate the longitudinal seam weld length as the vessel
component length multiplied by the number of long seams specified.
Transitions and Conical Skirts
Coster determines the required plate length and width using the same method as How Coster
Determines The Layout of Conical Sections on page 11-6 but instead of comparing the required
plate size to the stock plate sizes available, Coster compares the required plate size to the maximum
allowable plate width and maximum allowable plate length dimensions (user defined defaults on the
Fabrication dialog of the Defaults - Other menu). As in the method described above, the number of
segments is increased until the minimum number of segments can be accommodated on the plate
size described using the maximum allowable plate width and length and if more than 12 segments
are required Coster will split the cone into two separate cones of equal axial length by adding a girth
seam.
The scrap area and circumferential and longitudinal seam weld lengths are calculated as in How
Coster Determines The Layout of Conical Sections on page 11-6. Scrap material cost is included
for these custom cut components.
Segment cutting labor to cut out the individual pieces required to fabricate the component is also
included but plate cutting labor (labor required to cut the required plate size from a larger stock
plate) is not included since the plate size is the required size and does not need to be cut from a larger
stock plate.
cutting length = circumferential seam weld length + longitudinal seam weld length
Skirt Base Rings
For skirt base ring custom plate components, the circumferential seam weld length is calculated as
the fillet weld length (includes welding inside and outside the skirt), and the longitudinal seam weld
length is calculated as the groove weld length (welding used to join the base ring segments).
fillet weld length = 2 skirt OD

base ring OD base ring ID
base ring width = ------------------------------------------------------------------2
groove weld length = number of segments base ring width
Skirt base rings cut as one segment have no seams so the groove weld length is zero.
Coster selects the plate size and layout of the skirt base ring similar to the methods described in the
Skirt Base Ring Calculations on page 11-52 and in How Coster Determines The Layout of Skirt
Base Rings on page 11-9 with the following exception. Instead of comparing the required plate
size to the stock plate sizes available, Coster compares the required plate size to the maximum
allowable plate width and maximum allowable plate length dimensions (user defined defaults on the
Fabrication dialog of the Defaults - Other menu). If the user defined maximum allowable plate
width and plate length dimensions are too small to allow Coster to create a base ring layout using
from 1 to 6 segments, an error message is displayed showing the plate dimensions required to lay out
the base ring in 6 segments so that you can adjust the maximum allowable plate length and width
dimensions on the Fabrication dialog of the Defaults - Other menu before estimating the vessel
again.
Segment cutting labor and scrap material cost are included for the skirt base ring as shown in the
Skirt Base Ring Calculations on page 11-52 since the base ring must be cut from the plate size
specified either in one piece or nested sections. Plate cutting labor is not included since the plate
size is the required size and does not need to be cut from a larger stock plate.
Purchased Cylinders
Since some shops may purchase cylinders rather than fabricating them an option is available on the
Fabrication dialog of the Defaults - Other menu to indicate whether the cylinders are purchased
formed and tacked only or formed, tacked, and welded. Coster includes two separate tables for
purchased cylinders -- Cylinder Costs (formed/tacked) and Cylinder Costs (welded). Pricing for
purchased cylinders will be read from these tables and fabrication hours and costs (forming, cutting)
will be eliminated from the estimate. If the cylinders are purchased formed and tacked only then the
longitudinal seam weld length will be calculated according to the length of the component
multiplied by the number of seams (based on diameter) from the Diameter/Longitudinal Weld
Seams Ratio dialog on the Defaults - Welding menu.
Cylinder Calculations
Coster estimates cylinders made from pipe material according to the pipe size and pipe schedule.
After determining the size and schedule Coster looks up the Pipe Cost Schedule database table to
find the material cost per foot. Using the pipe material waste or the pipe minimum cut length from
the Fabrication dialog on the Defaults - Other menu Coster calculates the total material cost
including waste for pipe (if the length of pipe is less than the pipe minimum cut length then the
minimum cut length is used for estimating; otherwise the pipe material waste is used).
Cylinders fabricated from plate material are estimated using the stock plate size(s) that Coster
selects to cut out the cylinder. Refer to How Coster Determines Material Layout and Plate
Requirements (Default Method) on page 11-3 for the method that Coster uses to select plate sizes.
Plate unit cost is read from the Plate Costs table. Material cost for fabricated cylinders is calculated
using the finished weight and the plate unit cost. The stock plate used for cutting out the cylinder is
accounted for in the Weight of Source Material column and in the listing of plate usage in the Bill of
Materials. Cutting length is calculated based on the cutting layout and the cutting labor rate is read
from the Miscellaneous Fabrication Labor table. Forming labor hours for fabricated cylinders are
read from the Cylinder Forming Labor table.
For purchased cylinders the material cost is read from the Cylinder Costs (formed/tacked) or
Cylinders Costs (welded) table. The exact dimensions of the cylinder are used to calculate weight in
the Weight of Source Material column. Cutting and forming labor are eliminated for purchased
cylinders.
For both fabricated and purchased cylinders made from pipe and plate materials, other properties
(metallurgy, material density, welding rod density, normalization and impact test premiums) are
found on the Material Properties database table. Normalization and impact test premiums are added
to the material cost if required (see Normalization and Impact Testing on page 11-93).
Circumferential seam welding and longitudinal seam welding are calculated using the weld
deposition rate tables (Weld Deposition Rate - Circumferential Seam Weld and Weld Deposition
Rate - Longitudinal Seam Weld) based on the type of welding selected from the Weld Detail dialog
on the Defaults - Welding menu. Blasting and cleaning are calculated according to the type of
blasting selected on the User Selectable Items dialog and the user defined defaults values on the
Blasting/Cleaning dialog on the Defaults - Finishing menu. Grinding of the seams is calculated
from values on the Grinding table according to the selections on the User Selectable Items dialog.
Labor hours to fit up the cylinder to the attached component are read from the Fitup Labor tables.
The COMPRESS .xml file provides the following information:
-
thickness
ID
OD
length
pipe nominal size and schedule
radiography of longitudinal and circumferential seams
description of attached component (material, ID, OD, thickness)
whether the material is normalized
whether the material is impact tested
weight
material
For cylinders made from pipe material:
From the Pipe Cost Schedule table find the cost per unit length. Read the Material
Properties table to find material density, weld rod density, weld rod unit cost,
normalization and impact testing factors, and metallurgy.
For cylinders made from plate material:
Read the Plate Costs table to find plate cost. Read the Material Properties table to find
material density, weld rod density, weld rod unit cost, normalization and impact testing
factors, and metallurgy.
For purchased cylinders:
Read the Cylinder Costs (formed/tacked) or Cylinder Costs (welded) table to find the
cylinder cost. Read the Material Properties table to find material density, weld rod
density, weld rod unit cost, normalization and impact testing factors, and metallurgy.
Material Costs
pipe material cost = length of pipe/12 x pipe cost per ft

plate weight = finished weight from COMPRESS
plate material cost = plate weight x plate cost per lb
purchased material cost = cylinder cost from table
Coster uses an internal procedure to determine the plate dimensions of each piece
required to fabricate the cylinder and the plate size from which each of these pieces will
be cut (see How Coster Determines Material Layout and Plate Requirements (Default
Method) on page 11-3).
weld rod weight = (length x weld area x weld rod density) / weld recovery
weld rod material cost = weld rod weight x weld rod cost per lb
Labor Hours and Labor Costs
Forming Labor
pipe - no forming hours
plate - read from the Cylinder Forming Labor table based on thickness and cylinder ID
purchased cylinder - no forming hours
forming labor cost = forming labor hrs x manufacturing labor rate
Fitup Labor
If this cylinder is attached to another cylinder, then the fitup labor hours are read from
the Fitup Labor - Cylinder/Cylinder table based on the thickness and diameter of the
cylinder with the larger outer diameter or the thickness and diameter of this cylinder
when the outer diameter of both cylinders is equal. Similarly, if this cylinder is attached
to a transition the fitup labor hours are read from the Fitup Labor - Cylinder/Transition
table based on the thickness and diameter of the cylinder. If this cylinder is attached to a
head the fitup labor hours are included with the head.
fitup labor cost = fitup labor hrs x manufacturing labor rate
Cutting Labor
pipe - no cutting labor hours
plate - read the cutting rate based on the cylinder thickness and metallurgy from the
Miscellaneous Fabrication Labor table. The total cutting length is calculated according
to the plate dimensions Coster has determined for each piece required to fabricate the
cylinder.
purchased cylinder - no cutting labor hours
total cutting length cutting rate

total cutting hours = --------------------------------------------- --------------------------12
60
Long Seam and Girth Seam Labor Hours

pipe - no longitudinal seam welding, only circumferential welding calculated similarly
to plate welding labor hours
plate
length weld area weld rod density

labor hrs = -----------------------------------------------------------------------------------------weld deposition rate --------------------------------------------------------operator weld efficiency
purchased cylinder - longitudinal seam welding is included for cylinders purchased
formed and tacked only and circumferential welding is calculated similarly to plate
welding labor hours
labor cost = labor hrs x welding labor rate
Bevelling Labor
The top and bottom bevel lengths are both the "y" dimension of the required plate size(s)
used to fabricate the cylinder. The extra bevel length is the "x" dimension of the required
plate size(s) multiplied by 2 so that both sides of the seam are bevelled (this is usually
the longitudinal seam):
extra bevel length = 2 X required plate dimension

For cylinders custom cut to component size the extra bevel length is calculated:
extra bevel length = 2 X required plate dimension number of long seams

The total bevel length is:
bevel length = top bevel length + bottom bevel length + extra bevel length
The Item Labor Cost column on the estimate totals all the labor costs for the cylinder.
total labor cost = long seam labor cost + forming labor cost + fitting labor cost +cutting
labor cost + girth seam labor cost + blasting /cleaning labor cost + grinding labor cost
Surface Area
OD length
outside surface area = --------------------------------------144
ID length
inside surface area = ------------------------------------144
Transition Calculations
Transitions are estimated using the stock plate size(s) that Coster selects to cut out the transition.
Refer to How Coster Determines The Layout of Conical Sections on page 11-6 for the method that
Coster uses to select plate sizes. Plate unit cost is read from the Plate Costs table. Material cost for
the transition is calculated using the finished weight and the plate unit cost. The stock plate used for
cutting out the transition is accounted for in the Weight of Source Material column and in the listing
of plate usage in the Bill of Materials. Cutting length is calculated based on the cutting layout and to
cut out the required plate size from a larger stock plate and the length to cut out each segment
required to fabricate the transition. The cutting labor rate is read from the Miscellaneous Fabrication
Labor table. Forming labor hours are read from the Cones and Skirts Forming Labor table.
Other properties (metallurgy, material density, welding rod density, normalization and impact test
premiums) are found on the Material Properties database table. Normalization and impact test
premiums are added to the material cost if required (see Normalization and Impact Testing on
page 11-93). Circumferential seam welding and longitudinal seam welding are calculated using the
deposition rate tables (Weld Deposition Rate - Circumferential Seam Weld and Weld Deposition
Rate - Longitudinal Seam) based on the type of welding selected from the Weld Detail dialog on the
Defaults - Welding menu. Blasting and cleaning are calculated according to the type of blasting
selected on the User Selectable Items dialog and the user defined default values on the Blasting/
Cleaning dialog on the Defaults - Finishing menu. Grinding of the seams is calculated from values
on the Grinding table according to the selections on the User Selectable Items dialog. Labor hours
to fit up the transition to the attached component are read from the Fitup Labor tables.
-
thickness
Small ID
Small OD
Large ID
Large OD
length (axial length)
weight
material
orientation of transition
radiography of longitudinal and circumferential seams
Determine the cone surface length, H, for calculating surface area.
Cone surface length, H =
( Large ID Small ID )
( axial length ) + --------------------------------------------------------2
2
Material Costs
Read the Plate Costs table to determine plate cost. Read the Material Properties table to
determine metallurgy, material density, weld rod density, weld rod unit cost,
normalization and impact testing factors.
plate cost = plate weight x plate cost per lb
required to fabricate the transition and the plate size from which each of these pieces will
be cut (see Plate Selection on page 3-2).

weld rod weight = ---------------------------------------------------------------------------------------------weld recovery
Forming Labor
Read forming labor hours from the Cones and Skirts Forming Labor table based on
thickness and Large ID
Fitup Labor
If this transition is attached to a cylinder, then the fitup labor hours are read from the
Fitup Labor - Cylinder/Transition table based on the thickness and diameter of the
cylinder.
Cutting Labor
Read the cutting rate based on the transition thickness and metallurgy from the
Miscellaneous Fabrication Labor table. The total cutting length is calculated according
to the plate dimensions Coster has determined for each piece required to fabricate the
transition and the length to cut out each segment.

total cutting hours = -----------------------------------------------------------------------------12 60

labor hours = -----------------------------------------------------------------------------------------weld deposition rate --------------------------------------------------------operator weld efficiency
labor cost = labor hrs x welding labor rate
Bevelling Labor
Calculate bevel lengths where:
If the orientation of the transition from top to bottom is Small to Large calculate the top
and bottom bevel length:
DS
top bevel length = -----------------------------------------------number of segments
DL
bottom bevel length = -----------------------------------------------number of segments
If the orientation of the transition from top to bottom is Large to Small calculate the top
and bottom bevel length:
DL
top bevel length = ----------------------------------------------number of segments
DS
bottom bevel length = ----------------------------------------------number of segments
The extra bevel length is the cone surface length, H multiplied by 2 so that both sides of
the seam are bevelled:
extra bevel length = 2 cone surface length, H

Surface Area
0.5 cone surface length, H ( Large OD + Small OD )

outside surface area = ----------------------------------------------------------------------------------------------------------------------------------------------144
0.5 cone surface length, H ( Large ID+Small ID )
inside surface area = --------------------------------------------------------------------------------------------------------------------------------144
Vacuum Rings Calculations
Estimating vacuum rings is slightly different for files saved in Compress 5.x and Compress 6.x.
Compress 6.x allows the user to input values for weld size, welding spacing, weld length, type of
welding (intermittent, continuous, one or two sides), and whether the rings are inside or outside the
vessel. If the weld spacing and weld length values are both zero then Coster assumes that the
welding is 100% continuous. In Compress 6.x the neutral axis for rings is calculated to take into
consideration how the ring bends when it is rolled. This neutral axis is used in Coster to calculate
the total ring circumference. These inputs are used to calculate the welding to attach the ring to the
shell.
Compress 5.x rings are always outside the vessel and weld size and type of welding are determined
according to the user defined default settings within Coster (weld size is the value for Vacuum Ring
Fillet Weld Size and type of welding is made up of two values -- Vacuum Ring Intermittent Welding
(percent to weld) and Vacuum Ring Welding (1 side or 2 sides)). These vacuum ring default settings
are found on the Weld Detail dialog of the Defaults - Welding menu and are used to calculate the
welding to attach the ring to the shell.
Compress 6.x and Compress 5.x files
According to the material, structural type and size of the vacuum ring, Coster looks up the $/lb
material cost from the Structures/Rings/Tray Supports Material Costs table. The material cost for
vacuum rings is calculated using the finished weight and normalization and impact test premiums
are added if required (see Normalization and Impact Testing on page 11-93). Metallurgy, welding
rod density, weld rod unit cost, and normalization and impact test premiums are read from the
Material Properties table. The vacuum ring weld deposition rate used to calculate butt welding labor
hours is a user defined default value on the Weld Detail dialog of the Defaults - Welding menu.
Coster assumes there is one butt weld used to join the rings for every 10 feet of shell circumference.
An extra butt weld is added for any remainder. The weld gap used in the calculation is the maximum
of the user defined default weld gap (Weld Detail dialog on the Defaults - Welding menu) and 1/8
inches. Forming labor hours for vacuum rings are read from the Vacuum Ring Labor table.
-
cross section area
density
inside shell corrosion allowance
outside shell corrosion allowance
vacuum ring ID (ring ID) -- this is equal to the shell OD
vacuum ring OD
whether the rings are inside or outside the vessel
weld configuration (intermittent or continuous and welding 1 or 2 sides)
vacuum ring fillet weld size (leg size)
weld spacing
weld length
ring width
ring depth
neutral axis for rings in the x direction
weight
vacuum ring material
vacuum ring description (size and type of vacuum ring -- flat bar, equal leg angle,
unequal leg angle, I beam/wide flange, structural tee, user defined)
Other parameters are:

-
vacuum ring weld deposition rate (ring weld deposition rate)
Calculations for vacuum rings for vessels designed using Compress 5.x and the Vessel
Modeler are different than for vessels designed using Compress 6.x. The Compress 6.x
vessel design contains additional information that is used in the calculations.
COMPRESS 5.x and Vessel Modeler
Calculations for Compress 5.x and Vessel Modeler vessels use the Coster values for
vacuum ring fillet weld size, vacuum ring welding 1 or 2 sides, and vacuum ring
intermittent welding from the Weld Detail dialog on the Defaults - Welding menu.
total ring circumference = shell OD

Calculate the ring to shell weld volume based on the leg size, total ring
circumference, welding on one or two sides and the percent of welding (intermittent
or 100%).
ring to shell weld volume

2
leg
size ------------------ sides to weld total ring circumference intermittent welding
2
= --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------100
COMPRESS 6.x
Compress 6.x vessels provide additional information for rings. The Coster values from
the Fillet Welds dialog on the Defaults - Welding menu for vacuum ring fillet weld size,
vacuum ring welding 1 or 2 sides, and vacuum ring intermittent welding will not be used
since these values are provided within the Compress 6.x vessel design.
Calculate the total ring circumference.
total ring circumference = ( ring ID + 2 neutral axis for rings )

Calculate the percentage of welding required. If the weld length and the weld spacing
entered are both zero then Coster assumes that the welding is 100% continuous.
(percent to weld = 1)
weld length
percent to weld = -----------------------------------------------------------------weld length + weld spacing
Calculate the ring to shell weld volume using the total ring circumference and percent to
weld according to the type of welding selected in the Compress 6.x vessel design.
In-Line Intermittent and Staggered Intermittent
sides to weld = 2
ring to shell weld volume =

2
leg size
---------------------- sides to weld total ring circumference percent to weld
2
Continuous One Side, Intermittent Other Side
leg size 2
continuous side weld volume = ---------------------- total ring circumference
2
intermittent side weld volume =
2
leg size
---------------------- total ring circumference percent to weld
2
ring to shell weld volume =
continuous side weld volume + intermittent side weld volume
Continuous both sides

sides to weld = 2
2
leg size
ring to shell weld volume = ---------------------- sides to weld total ring circumference
2
Material Costs
Read Structures/Rings/Tray Supports Material Costs table to find the ring cost per lb for
the material, ring type and size. Read the Material Properties table to find metallurgy,
material density, weld rod density, weld rod unit cost, normalization and impact testing
factors.
weight = finished weight from Compress
material cost = weight x structure cost per lb
weld rod weight = ( ring butt weld volume + ring to shell weld volume )
weld rod density weld recovery
To calculate the number of butt welds for the ring we assume that there is one butt weld
for every 10 feet (or part of a foot) of outside shell circumference. Coster assumes that
the vacuum rings are purchased in 10 foot lengths.
ring butt welds = total ring circumference / 12 / 10
Because of the way rings are formed the weld gap will always be at least 0.125 in. To
calculate the ring butt weld volume Coster uses the maximum of either the weld gap or
0.125 in.
ring butt weld volume = cross section area maximum(weld gap or 0.125)
ring butt welds
ring butt weld volume weld rod density
ring labor hrs = -----------------------------------------------------------------------------------------------------------------------------ring weld deposition rate operator weld efficiency
ring labor cost = ring labor hrs x welding labor rate
Read the ring forming hours from the Vacuum Ring Labor table according to the
Shell OD.
forming cost = ring forming labor hrs x manufacturing labor rate
ring to shell weld volume weld rod density

girth labor hrs = ---------------------------------------------------------------------------------------------------------------------------ring weld deposition rate operator weld efficiency
girth seam cost = girth labor hrs x welding labor rate
2:1 Heads, F&D Heads, Hemispherical Heads Calculations

Coster assumes that all heads are purchased. The head cost is found on the corresponding Head
Costs table based on the head nominal thickness and material specification. If Coster cannot read or
interpolate a head cost from the Head Costs tables then you will be asked to provide a cost.
Metallurgy, material density, welding rod density, welding rod unit cost, and normalization and
impact test premiums are read from the Material Properties table. Normalization and impact test
page 11-93). Labor hours to bevel the head are read from the Head Bevel Labor table.
Circumferential seam welding is calculated using the Weld Deposition Rate - Circumferential Seam
Weld table based on the type of welding selected from the Weld Detail dialog on the
Defaults - Welding menu. Blasting and cleaning are calculated according to the type of blasting
on the Grinding table according to the selections on the User Selectable Items dialog.
-
thickness
ID
material
description of attached component (material, ID, OD, thickness and whether it is
attached on the left or right side of the head)
weight
lined head volume in US gallons (the lining volume is subtracted from the head
volume)
straight flange length
Material Costs
Read the Material Properties table to find metallurgy, material density, weld rod density,
weld rod unit cost, normalization premium, impact testing factors.
Read the head costs table (2:1, F&D, Hemispherical) to find the head cost based on the
head OD, head nominal thickness, and material.

weld rod weight = -----------------------------------------------------------------------------------------weld recovery
Fitup Labor
If this head is attached to a cylinder or another nozzle, then the fitup labor hours are read
from the Fitup Labor - Head/Cylinder table based on the thickness and diameter of the
cylinder or nozzle.
Head Bevel Labor Hours
The labor hours to bevel the head are read from the Head Bevel Labor table based on the
straight flange thickness and the outer diameter. The head bevel labor hours are reported
as part of the forming labor hours.
head bevel labor cost = head bevel labor hrs x manufacturing labor rate
Longitudinal labor costs are zero for heads. Coster uses the mid-circumference as the
weld length for heads.
girth seam labor hrs = ( weld area weld length weld rod density )
weld deposition rate operator weld efficiency
girth seam cost = girth seam labor hrs x welding labor rate
Surface Area for 2:1 Heads
2
( 1.084 OD ) + ( OD straight flange length )

outside surface area = ---------------------------------------------------------------------------------------------------------------------------144
2
( 1.084 ID ) + ( ID straight flange length )

inside surface area = -----------------------------------------------------------------------------------------------------------------------144
Surface Area for F&D Heads
2
( 0.9286 OD ) + ( OD straight flange length )

outside surface area = ------------------------------------------------------------------------------------------------------------------------------144
( 0.9286 ID ) + ( ID straight flange length )

inside surface area = --------------------------------------------------------------------------------------------------------------------------144
Surface Area for Hemispherical Heads
2
( ( OD 2 ) ) + ( OD straight flange length )

outside surface area = -----------------------------------------------------------------------------------------------------------------------------144
2
( ( ID 2 ) ) + ( ID straight flange length )

inside surface area = -------------------------------------------------------------------------------------------------------------------------144
Flat Heads Calculations
Coster estimates material costs, fitup and welding labor for flat head sketches (b-1), (b-2), (c), (d),
(e), (f), (g) and (h).
Metallurgy, material density, welding rod density, welding rod unit cost, and normalization and
impact test premiums are read from the Material Properties table. Normalization and impact test
page 11-93). Bevelling of the flat head and hydrotest are not considered. Blasting and cleaning are
calculated according to the type of blasting selected on the User Selectable Items dialog and the user
defined default values on the Blasting/Cleaning dialog on the Defaults - Finishing menu. Grinding
of the seams is calculated from values on the Grinding table according to the selections on the User
Selectable Items dialog. Paint and primer are calculated according to the selections on the user
Selectable Items dialog.
-
thickness
OD
material
flat head sketch
description of attached component (material, ID, OD, thickness and whether it is
attached on the left or right side of the head)
weight
Other parameters are

-
waste from flame cutting

bevel angle (nozzle groove welds) (nozzle weld angle)
weld gap
Material Costs
determine metallurgy, material density, weld rod density, weld rod unit cost,
normalization and impact testing factors.
Coster assumes that there is plate material available for cutting out the flat head. The
size that Coster displays on the Bill of Materials is a square with dimensions of the flat
head OD plus 2 times the waste from flame cutting. The scrap material for the flat head
is based on this plate size.
plate width = ( OD + 2 flame cutting waste )

plate length = ( OD + 2 flame cutting waste )
OD 2
area of flat head = --------
2
scrap material = plate width plate length area of flat head
Cutting Labor
Read the cutting rate based on the flat head thickness and metallurgy from the
Miscellaneous Fabrication Labor table. The cutting length is calculated below
depending upon whether or not the head is seamless.
Cutting length for seamless flat head
total cutting length = OD

Cutting length for flat head (Coster assumes that there is one seam in the center)
total cutting length = ( OD ) + ( 2 OD )

total cutting hours = --------------------------------------------- --------------------------12
60
Fitup, Layout, and Machining Labor

Fitup labor hours for flat head sketches (c), (e), (f), (g) and (h) are read from the Head
Flat Fitup Labor table based on the flat head OD and thickness. Fitup labor hours for flat
head sketches (b-1), (b-2) and (d) are read from the Fitup Labor - Head/Cylinder table
based on the attached component OD and attached component thickness. Read the
layout labor hours from the Head Flat Fitup Labor table and the machining labor hours
from the Head Flat Machining Labor table for all flat head sketches based on the flat
head OD and thickness. Fitup, layout, and machining labor costs are calculated using the
manufacturing labor rate.
labor cost = labor hrs x manufacturing labor rate
Welding Labor
local shell thickness = thickness of attached component from Compress .xml file
The fillet weld length, fillet weld area, groove weld length, and groove weld area are
calculated according to the flat head sketch as shown below.
a)
Sketches (b-1), (b-2), (d)
fillet weld length = 0

fillet weld area = 0
fillet weld hours = 0
If there is an attached component (cylinder, 2:1 head or f&d head) then the groove weld
area is calculated as follows similar to the nozzle v groove weld where the groove size is
the local shell thickness. Otherwise the groove weld area and groove weld length are
both zero.
2
Area A = 0.5 local shell thickness tan ( nozzle weld angle )

Area B = weld gap local shell thickness
groove weld area = Area A + Area B
= nozzle bevel angle
groove weld length = OD

Read the girth seam weld deposition rate from the Weld Deposition
Rate - Circumferential Seam Weld table based on the local shell thickness and
metallurgy.
groove weld hours = ( ( groove weld area groove weld length weld rod density )
girth seam weld deposition rate operator weld efficiency
b)
Sketches (c), (e) and (f)
The fillet weld length is multiplied by 2 to include two fillet welds (double fillet lap
attachment weld).
fillet weld length = OD 2

2
local shell thickness

fillet weld area = -------------------------------------------------2
Read the fillet welding rate from the Miscellaneous Fabrication Labor table based on the
local shell thickness and metallurgy.
fillet weld hours = ( fillet weld length 12 ) fillet welding rate

groove weld length = 0
groove weld area = 0
groove weld hours = 0
c)
Sketch (g)
fillet weld length = 0

fillet weld area = 0
fillet weld hours = 0

The groove weld area is calculated as follows similar to the nozzle v groove weld where
the groove size is the flat head thickness. This is a full penetration groove attachment
weld at the head circumference.
2
Area A = 0.5 flat head thickness tan ( nozzle weld angle )

Area B = weld gap flat head thickness
Read the groove welding rate from the Miscellaneous Fabrication Labor table based on
the flat head thickness and metallurgy.
groove weld hours = ( groove weld length 12 ) groove welding rate

d)
Sketch (h)
This is a full penetration shell to head attachment weld with cover fillet weld (only one
fillet weld in this case).
fillet weld length = OD

minimum thickness = minimum ( flat head thickness or local shell thickness )
2
minimum thickness
fillet weld area = ------------------------------------------------2
The groove weld area is calculated as follows similar to the nozzle v groove weld where
the groove size is the local shell thickness:
2
Area A = 0.5 local shell thickness tan ( nozzle weld angle )

Area B = weld gap local shell thickness
Read the fillet welding rate and the groove welding rate from the Miscellaneous
Fabrication Labor table based on the local shell thickness and metallurgy.
fillet weld hours = ( fillet weld length 12 ) fillet welding rate

groove weld hours = ( groove weld length 12 ) groove welding rate
Long Seam Labor Hours
If there is not a head longitudinal joint then the long seam labor hours are zero.
Otherwise, if there is a head longitudinal joint calculate the longitudinal seam welding
labor. Read the longitudinal seam weld deposition rate from the Weld Deposition
Rate - Longitudinal Seam Weld labor table based on the metallurgy and the flat head
thickness.
Coster uses the flat head OD as the weld length.
long seam labor hrs = ( weld area weld length weld rod density )
Surface Area for Flat Heads
OD 2
area of flat head = --------
2
area of flat head edge = OD flat head thickness
outside surface area = ( area of flat head + area of flat head edge ) 144
exposed inside head diameter = OD ( 2 flat head thickness )
2
inside surface area = ( exposed inside head diameter 4 ) 144

The fillet weld volume and groove weld volume are calculated based on the area and length
calculated above.
fillet weld volume = fillet weld area fillet weld length

groove weld volume = groove weld area groove weld length
( fillet weld volume + groove weld volume ) weld rod density
weld rod weight = ------------------------------------------------------------------------------------------------------------------------------------------------------weld recovery
weld rod material cost = weld rod weight weld rod cost per lb
Body Flange Calculations
ASME B16.5/16.47 and ASME Section VIII Division 1 Appendix 2
-
flange ID
flange OD
length
flange length, e
thickness
description of attached component (material, ID, OD, thickness and whether the
attached component is made from a plate of pipe material -- if made from pipe
material then the pipe schedule and nominal size are provided)
whether there is a hub present
hub thickness, G0
hub length
whether it is an ASME B16.5/16.47 or ASME Section VIII Division 1
Appendix 2 flange
number of bolts
bolt diameter
groove weld size
upper fillet weld size
lower fillet weld size
lap fillet weld size
lap thickness
whether there is a blind attached
flange weight
blind weight (if there is a blind attached)
flange type (WN, SO, TH, SW, LJ, ring type integral, ring type full face gasket,
ring type loose, weld neck integral, slip on full face gasket, slip on loose, slip on
integral, lap joint loose, split loose, reverse integral, reverse loose)
class
flange material
flange nominal size
This calculation does not apply to bare pipe, long weld necks or couplings. Hydrotest
hours are not considered for ASME B16.5/16.47 or ASME Section VIII Division 1
Appendix 2 body flanges.
If the attached component is a pipe material, look up the appropriate Pipe Cost Schedule
table for metallurgy.
Material Costs
Read the Material Properties table to find the metallurgy and weld rod unit cost based on
the flange material.
ASME B16.5/16.47 flange:
Read the flange cost from the appropriate flange table based on the flange material,
flange nominal size and class (for weld neck type the bore size is also required). The
flange cost is reported in the material cost column of the estimate.
ASME Section VIII Division 1 Appendix 2 flange:
Read the plate cost from the Plate Cost table based on the flange material, flange OD,
and flange thickness.
material cost = plate cost per lb flange weight

If there is an ASME B16.5/16.47 blind attached it is reported as a separate item in the
shell section of the estimate. Read the blind cost from the blind cost table based on the
flange material, class, flange facing and flange nominal size. The blind cost is reported
in the material cost column of the estimate. If there is a blind attached to the ASME
Section VIII Division 1 Appendix 2 flange, it will be estimated as a separate
component -- bolted cover.
ASME B16.5/16.47 flange labor:

Read the Flange To Nozzle - Fitup Labor table to find labor hours to fit up the flange
to the nozzle based on the flange type (weld neck flange or other ASME B16.5/16.47
flange), metallurgy, OD and pipe schedule (see Flange Cost/Flange Labor on page
11-73 for lookup method). The fitup labor cost is calculated using the manufacturing
labor rate.
flange fitup labor cost = flange fitup labor hrs x manufacturing labor rate
Read the Flange To Nozzle - Welding Labor table to find labor hours to weld the
flange to the nozzle based on the flange type (weld neck flange or other ASME
B16.5/16.47 flange), metallurgy, OD and pipe schedule (see Flange Cost/Flange
Labor on page 11-73 for lookup method). Read the girth seam weld deposition rate
from the Weld Deposition Rate - Circumferential Seam Weld table based on the
thickness and metallurgy. The welding labor hours are reported in the long seam
labor column of the estimate and the welding labor cost is calculated using the
welding labor rate.
flange welding labor cost = flange welding labor hrs x welding labor rate
weld rod weight = girth weld deposition rate x flange welding labor hrs
weld rod cost = weld rod weight x weld rod cost per lb
If there is an ASME B16.5/16.47 blind attached, read the blind labor hours from the
Blind Flange Labor table based on the class and the flange nominal size. Otherwise
the blind labor hours are zero. The blind labor is reported in the forming labor hours
column of the estimate and the blind labor cost is calculated using the manufacturing
labor rate.
ASME Section VIII Division 1 Appendix 2 flange labor:
Read the machining labor hours from the Machining Labor table based on flange
type, hub detail and flange ID.
Read the drilling per minute rate from the Drilling Labor table based on flange
material and bolt nominal size.
drilling labor hours = drilling per minute rate flange thickness 60

number of bolts
ASME Section VIII Division 1 Appendix 2 flange welding:
Ring Type Integral
no circumfrential butt weld present
groove weld length = ( flange ID + groove weld size )

upper fillet weld length = ( flange ID upper fillet weld size )
lower fillet weld length = ( flange ID + lower fillet weld size )
Slip On Integral
no cirumferential butt weld present
groove weld length = ( flange ID + hub thickness, G0 groove weld size )

upper fillet weld length = ( flange ID + upper fillet weld size )
lower fillet weld length = ( flange ID + hub thickness, G0
lower fillet weld size )
Calculate the total weld length for ring type integral and slip on integral flange:
total weld length = groove weld length + upper fillet weld length
+ lower fillet weld length
Fabrication Labor table based on metallurgy and weld size to calculate the upper
fillet weld, lower fillet weld and groove weld hours for ring type integral and slip on
integral flange:
fillet weld hours = fillet weld rate ( fillet weld length 12 )

groove weld hours = groove weld rate ( groove weld length 12 )
Calculate the welding rod weight as follows:
2
groove weld area = ( groove weld size ) 2

2
upper fillet weld area = ( upper fillet weld size ) 2

upper fillet weld volume = upper fillet weld area upper fillet weld length
2
lower fillet weld area = ( lower fillet weld size ) 2

lower fillet weld volume = lower fillet weld area lower fillet weld length
flange welding rod weight = ( groove weld volume + upper fillet weld volume
+ lower fillet weld volume ) welding rod density weld recovery
Ring Type Full Face Gasket, Ring Type Loose, Slip On Full Face Gasket, Slip On
Loose
no circumferential butt weld present

2


flange welding rod weight = ( upper fillet weld volume
Calculate the total weld length for ring type full face gasket, ring type loose, slip on
full face gasket and slip on loose flange.
total weld length = upper fillet weld length + lower fillet weld length
Read the fillet welding rate from the Miscellaneous Fabrication Labor table based on
metallurgy and weld size to calculate the upper fillet weld and lower fillet weld hours
for ring type full face gasket, ring type loose, slip on full face gasket and slip on
loose flange:

Weld Neck Integral
no fillet welds present
circumferential seam weld length = ( flange ID + hub thickness, G0 )

If there is a component attached calculate the circumferential seam area using the
flange ID and hub thickness, G0.
Reverse Integral
circumferential seam weld length = ( flange OD hub thickness, G0 )

flange OD and hub thickness, G0.
Reverse Loose
circumferential seam weld length = ( flange OD + hub thickness, G0 )

Read the circumfential weld deposition rate from the Welding

Time - Circumferential Seam Weld table based on the hub thickness, G0, weld type
and metallurgy.
circumferential seam volume = circumferential seam area

circumferential seam weld length
Calculate welding rod weight as follows:
flange welding rod weight = circumferential seam volume

welding rod density weld recovery
Lap Joint Loose, Split Loose
There is no welding at all unless a welded lap is specified. If it is a welded lap then
the following welds are present:
groove weld length = flange ID

2
groove weld area = ( lap thickness ) 2

fillet weld length = flange ID
total weld length = groove weld length + fillet weld length

2
upper fillet weld area = ( lap thickness ) 2

upper fillet weld volume = upper fillet weld area fillet weld length
flange welding rod weight = ( groove weld volume + upper fillet weld volume )
Read the fillet welding rate based on metallurgy and lap fillet weld size and the
groove welding rate based on metallurgy and lap thickness from the Miscellaneous
Fabrication Labor table to calculate the fillet weld and groove weld hours for lap
joint loose and split loose flange:
weld hours = weld rate ( weld length 12 )

Surface Area
outside surface area = ( flange OD flange length ) 144

ASME B16.5/16.47 flange:
inside surface area = ( flange ID flange length ) 144

Surface area for weld neck integral, lap joint loose, split loose, and reverse loose:
inside surface area = ( flange ID flange length ) 144

Surface area for all other types (ring type integral, ring type full face gasket, ring type
loose, slip on full face gasket, slip on loose, slip on integral, reverse integral:
inside surface area = ( flange ID flange length, e ) 144

Packed Bed Calculations
For packed beds only the weight is reported on the estimate.
-
weight
Platform/Ladder and Top Head Platform Calculations

Coster reports the square footage of the platform and the total platform weight which includes the
weight of the platform, railing and ladder. The cage weight is included in the ladder weight. Coster
also reports the platform, railing, and ladder material costs, labor hours and labor costs using the
lookups from the Platform/Ladder Cost and Labor table. Due to the format of this table no
interpolation will be made.
-
platform weight (includes railing and ladder weight)

platform length
platform width
railing linear weight (lb/ft)
ladder weight per linear ft (ladder weight also includes the weight of the cage)
grating weight
platform distance to datum
ladder distance to datum
Square Footage and Weight
Coster calculates the square footage of the platform and the total weight, which includes
platform weight, railing weight, and ladder weight.
ladder length = ( abs ( platform distance to datum ladder distance to datum ) ) 12

ladder weight = ladder length ladder weight per linear ft
The ladder weight includes the cage weight as part of the lb/linear ft cost.
railing length = 2 ( platform length + platform width )

railing weight = railing length 12 railing linear weight
platform weight = platform weight railing weight ladder weight
platform weight
platform square footage = -------------------------------------------------------------------------------------------weight of one sq ft of platform grating
Platform, Railing, Ladder Material Cost and Labor Hours
The material cost per lb and labor hrs per lb for the platform, railing and ladder are read
from the Platform/Ladder Cost and Labor table. The material cost is displayed in the
Material Cost column and the labor hours are displayed in the Install or Other Labor
column of the estimate.
platform material cost = platform weight x platform cost per lb
platform labor hours = platform weight x platform labor hours per lb
railing material cost = railing weight x railing cost per lb
railing labor hours = railing weight x railing labor hours per lb
ladder material cost = ladder weight x ladder cost per lb
ladder labor hours = ladder weight x ladder labor hours per lb
Tray Support Ring Calculations

Coster estimates tray supports labor using the Tray Installation Labor table and calculates the weight
for trays and tray supports. The tray support material, structural type and size is set on the Tray
Supports dialog on the Defaults - Other menu and using the cost per lb value from the Structures/
Rings/Tray Supports Material Cost table based on the material, structural type, and tray support size
Coster estimates the material cost of the tray supports. The properties (metallurgy, material density,
weld rod density, weld rod unit cost) are for the tray supports and are read from the Material
Properties table. Since the material cost for trays is so variable, the cost is a manual entry.
-
number of trays
tray elevation of bottom tray
space between trays
tray diameter
tray weight per area (sq ft)
tray support weight

-
vacuum ring weld deposition rate (ring weld deposition rate)

fillet weld size for vessel internals (leg size)
tray support material
structural type
size
leg size
shell surface
equal leg
angle
leg size
Material Costs
Read the Structures/Rings/Tray Supports Material Cost table to find the structure cost
per lb based on the material, structural type and size.
material cost = tray support weight per tray x structure cost per lb
Read the Material Properties table to find the metallurgy, weld rod density and weld rod
unit cost of the tray support material.
Calculate the tray support weld volume. The volume is for welding both the top and
bottom of the tray supports.
leg size
tray support weld volume = -------------------- tray diameter 2
2
weld weight = weld rod density x tray support weld volume
weld weight
weld rod weight = ---------------------------------weld recovery
girth labor hrs = weld weight / ring weld deposition rate / operator weld efficiency
girth seam cost = girth labor hrs x welding labor rate
Read the Tray Installation Labor table to find the tray support ring installation labor
hours based on the vessel ID.
installation labor cost = installation labor hrs x manufacturing labor rate
Weight
Calculate the cross sectional area of each tray.

2
cross section area = tray diameter 4 144

Calculate the total weight (tray and tray support weight).
total weight = (tray weight per sq ft x cross section area) + tray support weight
Insulation/Lining Calculations
The weight, thickness, and density for insulation and lining are reported on the estimate. Coster also
displays whether the insulation/lining is field installed or shop installed. If field installed then
material cost is reported as zero. If shop installed the material cost is calculated using the cost per
sq ft provided by the user during the costing process. To specify the type of installation (field or
shop) for insulation/lining set the user defined default on the Insulation or Lining dialog on the
Defaults - Clips menu. The number of clips is calculated with the user defined Insulation/Lining
Coverage default value from the Insulation or Lining dialog on the Defaults - Clips menu. Similarly
the material cost for clips and the labor hours per clip are calculated with the user defined Insulation/
Lining Clips ($/clip) and Insulation/Lining Clip Labor (hrs/clip) default values.
thickness
density
weight
Other parameters are:

-
insulation/lining coverage (sq ft coverage per clip)

insulation/lining clips (clip cost each)
insulation/lining clip labor (labor per clip)
Material Costs
Calculate the insulation/lining material cost and the total clips cost. The cost per sq ft of
the insulation/lining will be manually input if the insulation/lining is shop installed.
Otherwise the material cost will be zero.
surface area = ( weight density ) ( thickness 12 )

material cost = surface area x cost per sq ft
The total clip cost is displayed in the consumables cost column of the miscellaneous
section of the estimate.
total clip cost = number of clips x clip cost each
The labor hrs per 100 sq ft will be manually input during the estimate if the insulation/
lining is shop installed. Otherwise the labor hrs to install the insulation/lining will be
zero. Calculate labor hours.
labor hrs = (surface area / 100) x labor hrs per 100 sq ft
labor cost = labor hrs x manufacturing labor rate
Calculate the number of clips required to install the insulation (Coster rounds the number
of clips to the next full clip) and calculate the labor hours to install the clips.
number of clips = surface area / sq ft coverage per clip
labor hrs to install clips = number of clips x labor per clip
labor cost to install clips = labor hrs to install clips x manufacturing labor rate
Saddles Calculations
The saddle quantity on the estimate is always reported as 2. Coster calculates the weight of the wear
plate, base plate, web plate, and ribs according to the size of each component. Coster assumes that
the saddle width from the Compress .xml file is equal to the width of the end ribs and the width of
the inside ribs is the saddle width minus the web thickness.
Metallurgy, material density, welding rod density, and welding rod unit cost are read from the
Material Properties table. The plate unit cost for the web plate, wear plate if present, base plate, and
ribs is read from the Plate Costs table.
The plate dimensions for each saddle component are shown on the Bill of Materials sheet and are
listed as user defined plate sizes in the plate usage section. To determine these dimensions Coster
assumes that there is one waste from flame cutting added to the width and length of each plate cut
for the base plate, wear plate and web plate. Coster assumes that these plates are cut out from the
corner of a stock plate so the waste from flame cutting is added to only two sides of the rectangle.
Coster assumes that the ribs are sheared so there is no waste from flame cutting added to these plate
sizes. Scrap material for the web plate is calculated and included in the plate usage section of the
Bill of Materials. Normalization and impact test premiums are not considered for saddle
components.
The weld size for fillet welding on the saddles is read from the Saddle Fillet Weld Size value on the
Fillet Welds dialog of the Defaults - Welding menu. Labor hours to fit up the saddle and wear plate
if present are read from the Saddles Fitting Labor table. The Miscellaneous Fabrication Labor table
provides the cutting rate and fillet welding rate for each component.
The COMPRESS .xml file provides the following information
-
saddle width
saddle material waste (saddle waste)
shell OD at left saddle -- left saddle diameter (Shell OD)
overall saddle height from base plate to vessel long axis
number of ribs
whether wear plate is present
wear plate contact angle (wear plate angle)
wear plate width
wear plate thickness
base plate thickness
rib thickness
web plate thickness
base plate width (as viewed from the side of the vessel)
base plate length (around the vessel as viewed from the end of the vessel)
saddle contact angle ()
whether centered web or edge web (saddle type)
material
weight
The quantity for saddles displayed on the estimate is always 2.

-
saddle welding (1 or 2 sides of seam) (saddle sides to weld)

saddle fillet weld size (saddle leg size)
shell radius = Shell OD 2
Calculate the web plate height.

web plate height =
(overall saddle height-base plate thickness)-(shell radius x sin (90- / 2))
Calculate the wear plate arc length.
wear plate arc length = shell radius x wear plate angle
Calculate the wear plate weight if present.
wear plate length = wear plate angle x (shell radius + 0.5 x wear plate thickness)
wear plate weight = wear plate width x wear plate length x wear plate thickness x
material density
Calculate the base plate weight.
base plate weight = base plate length x base plate width x base plate thickness x material
density
If there are ribs present then calculate the rib width and the distance between end ribs (rib distance).
inside rib width = saddle width - web plate thickness
outside rib width = saddle width
rib distance = (Shell OD + 2 x wear plate thickness) x sin ( / 2)
For each pair of ribs, and center rib if present, Coster calculates the rib width, rib weight, rib height,
total rib weight, total rib cutting length, and total rib weld length. The saddle welding (1 side of
seam or 2 sides of seam) entry from the Fillet Welds dialog on the Defaults - Welding menu is used
to calculate the total rib weld length.
rib weight = rib height x rib width x rib thickness x material density
Calculate the web plate length, web plate arc length, web plate weld length, and wear plate weld
length.
web plate length = base plate length - (4 x rib thickness)
Coster uses 4 times the rib thickness to calculate the web plate length in the equation
above to account for a fillet weld on the outside of the end rib on each side.
web plate arc length = shell radius x
web plate weld length = (web plate length + web plate arc length + (2 x web plate
height)) x saddle sides to weld
wear plate weld length = wear plate arc length x 2 + wear plate width x 2
Calculate the web plate scrap area and the web plate weight.
web plate top scrap area = 0.5 x (shell radius + wear plate thickness) ^2 x ( - Sin( ))
web plate top scrap area
If the web plate length is greater than the rib distance then calculate extra scrap material
for the two areas outside the ribs. Otherwise the web plate side scrap area is zero.
web plate side scrap area = outside rib height x (web plate length - rib distance)
web plate side

scrap area
total web plate scrap area = web plate top scrap area + web plate side scrap area
web plate weight = (web plate length x web plate height - web plate scrap area) x web
plate thickness x material density
Welding is calculated as a fillet weld using the saddle fillet weld size default as the leg size.
Calculate the total weld volume by adding together the web plate weld volume, wear plate weld
volume, and the total rib weld volume.
saddle leg size 2

web plate weld volume = ------------------------------------- web plate weld length
2
saddle leg size 2
wear plate weld volume = ------------------------------------- wear plate weld length
2
2
saddle leg size

total rib weld volume = ------------------------------------- total rib weld length
2
total weld volume = web plate weld volume + wear plate weld volume + total rib weld
volume
Material Costs
Read the Plate Costs table to find web plate cost, base plate cost, rib cost and wear plate
cost. Divide each of the plate costs by 100 to get the plate cost per lb. Read the Material
Properties table to find metallurgy, material density, weld rod density, and weld rod unit
cost.
total base plate cost = (base plate weight x base plate cost per lb) + ((base plate weight x
base plate cost per lb) x (saddle waste / 100))
total wear plate cost = (wear plate weight x wear plate cost per lb) + (( wear plate weight
x wear plate cost per lb) x (saddle waste / 100 ))
saddle fitting cost = saddle fitting time x manufacturing labor rate
wear plate fitting cost = wear plate fitting time x manufacturing labor rate
rib cutting cost = rib cutting hrs x manufacturing labor rate
web plate cutting cost = web plate cutting hrs x manufacturing labor rate
base plate cutting cost = base plate cutting hrs x manufacturing labor rate
wear plate cutting cost = wear plate cutting hrs x manufacturing labor rate
weld rod weight = (total weld volume x weld rod density) / weld recovery
Read the Saddles Fitting Labor table to find the saddle fitting time and the wear plate
fitting time based on the Shell OD.
If there is no wear plate present then the total fitting time is equal to the saddle fitting
time.
total fitting time = saddle fitting time + wear plate fitting time
Read the Miscellaneous Fabrication Labor table to find the cutting rate (for ribs, web
plate, base plate, wear plate if present), and fillet welding rate based on thickness and
metallurgy.
rib cutting hrs = ((total rib cutting length /12) x rib cutting rate) / 60
web plate cutting length = web plate length + (web plate height x 2) + web plate arc
length
web plate cutting hrs = ((web plate cutting length /12) x web plate cutting rate) /60
base plate cutting length = (base plate width + base plate length) x 2
base plate cutting hrs = ((base plate cutting length / 12) x base plate cutting rate) /60
wear plate cutting length = (wear plate arc length + wear plate width) x 2
wear plate cutting hrs = ((wear plate cutting length /12) x wear plate cutting rate) /60
web plate weld hrs = fillet welding rate x (web plate weld length / 12)
wear plate weld hrs = fillet welding rate x (wear plate weld length / 12)
rib weld hrs = fillet welding rate x (total rib weld length / 12)
total rib weld hrs = rib weld hrs / operator weld efficiency
total wear plate weld hrs = wear plate weld hrs / operator weld efficiency
total web plate weld hrs = web plate weld hrs / operator weld efficiency
total welding hrs = total rib weld hrs + toal wear plate weld hrs + total web plate weld hrs
total welding labor cost = total welding hrs x welding labor rate
Surface Area
Calculate the surface area for base plate, web plate and ribs to estimate blasting,
cleaning, painting, and priming. The wear plate is not included as it becomes part of the
component to which it is attached and is therefore included in the blasting, cleaning,
painting and priming estimate for that component.
Base Plate
outside SA
= ( ( base plate length base plate width ) + ( base plate length base plate thickness )
+ ( base plate width base plate thickness ) ) 2 144
Web Plate
outside SA
= ( ( ( web plate length web plate height web plate scrap area ) 2 )
+ ( web plate arc length web plate thickness ) ) 144
Ribs
outside SA
( ( rib height rib width ) + ( rib height rib thickness ) + ( rib width rib thickness ) ) 2
= ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------144
Skirt Base Ring Calculations
Coster estimates the cost of the skirt base ring using a trial and error method to find the lowest total
cost for both labor and material. Depending on the size of the base ring and the available stock plate
sizes from the database table (see How Coster Determines The Layout of Skirt Base Rings on
page 11-9) Coster determines the labor and material costs required to fabricate the base ring in one,
two, three, four, five, and six segments. Coster selects a suitable plate for cutting while minimizing
the scrap produced by comparing the required plate area to the stock plate area. Coster will use drop
pieces first if suitable. Normalization and impact testing are not considered for skirt base rings. If
there are no suitable stock plates to fabricate the base ring in any of the one to six segment layouts
then Coster will display a plate size that will allow fabrication of the base ring in six segments. You
will be asked to provide a user defined plate size using the suggested dimensions (or larger
dimensions) to fabricate the base ring. Using this user defined plate size Coster repeats the process
to find the layout that produces the lowest total cost. On the estimate Coster reports the base ring
layout that generated the lowest total cost.
If possible Coster will reuse any rectangular plates (drop pieces) that remain after cutting out the
base ring and will list the unused drop pieces on the bill of materials sheet. All other leftover pieces
remaining after the base ring has been cut out will be considered scrap and will not be reused to
fabricate any remaining components. This scrap is listed by weight on the Bill of Materials sheet.
The Miscellaneous Fabrication Labor table provides the cutting rate, fillet welding rate (for welding
gussets and base to skirt), groove welding rate (for welding the base ring segments together) and
drilling rate per hole. The weld length to weld the base ring to the skirt includes welding both inside
and outside the skirt.
The base ring surface area includes both the top and bottom of the base ring and the inner and outer
surface of the base ring.
The gusset fillet weld size is determined using the minimum of the gusset thickness and the skirt
thickness. Similarly the fillet weld size (base to skirt weld size) is determined using the minimum of
the base ring thickness and the skirt thickness.
Blasting/Cleaning is calculated according to the type of blasting selected on the User Selectable
Items dialog and the user defined default values on the Blasting/Cleaning dialog on the
Defaults - Finishing menu. Grinding is calculated for both the top and bottom of the groove weld of
the skirt base ring based on the skirt base ring thickness.
The total gusset weight, total gusset weld length, and gusset surface area are determined according
to the base ring configuration.
a)
single base ring with gussets -- Coster assumes triangular gussets and the gusset
weld length includes welding on both sides of each gusset. Also included in the
weld length is the extra length (gusset height) if the skirt is flared. The number of
gussets is calculated as two times the number of bolts.
b)
single base ring with external chairs -- Coster assumes a rectangular shape for the
top plate. The number of chairs is equal to the number of bolts. Similar to the
single base ring with gussets the weld length includes welding on both sides of
each gusset and also includes the extra weld length due to a flared skirt. To
calculate the weld length for the top chair Coster assumes that the overhang is
equal to the gusset thickness.
c)
centered bolting chair -- The weld length includes welding on both sides of the
chair.
d)
double base ring -- The weld length includes any extra length due to a flared skirt.
Coster lists two entries on the estimate for double base rings -- one entry for the
base ring and a second entry for the compression ring. The first entry for base
ring follows the skirt base ring and double base ring section calculations below to
determine costs for the base ring and the gussets. The compression ring entry
follows the skirt base ring and single base ring with no gussets section
calculations below to determine costs for the compression ring. To calculate the
compression ring information using the formulas below substitute the
compression ring dimensions in place of the base ring dimensions.
base plate material

bolt material
description of attached skirt (material, ID, OD, thickness, angle)
base plate OD (Base OD)
base plate ID (Base ID)
base plate thickness
base ring weight
bolt circle
number of bolts
base configuration
whether gussets are present
gusset inside separation
gusset height (vertical)
gusset thickness (vertical)
compression ring/plate width out from skirt OD
compression plate/ring thickness
Read the Plate Costs table for plate cost. Read the Material Properties table to find metallurgy,
material density, weld rod density, and weld rod unit cost.
Calculate the base ring weld length. Multiply by two to include welding both the inside and the
outside of the skirt.
base ring weld length = 2 x (Skirt OD x )
Calculate the base ring surface area. Multiply by two to include the top and bottom of the ring.
2
base ring surface area = 2 ( 4 ) ( Base OD Base ID )

+ base plate thickness ( Base OD + Base ID )
Calculate the total gusset weight, total gusset weld length, and gusset surface area based on the type
of base plate configuration (single base ring with gussets, single base ring with external chairs,
double base ring, centered bolting chair, single base ring with no gussets). Welding of gussets is
done on both sides.
Single Base Ring With Gussets
Coster assumes triangular gussets. Calculate the number of gussets.

number of gussets = 2 x number of bolts
Calculate the gusset base, gusset face area, gusset volume, and gusset weight.
gusset base = (Base OD - Skirt OD) / 2
gusset face area = 0.5 x gusset base x gusset height
gusset volume = gusset face area x gusset thickness
gusset weight = gusset volume x material density
Calculate the gusset skirt side to consider the extra length for a flared skirt (for a straight
skirt the gusset skirt side is equal to the vertical gusset height).
gusset skirt side = gusset height / Cos (skirt angle)
Calculate the gusset weld length and multiply by two to include welding on both sides of
one gusset.
gusset weld length = 2 x (gusset base + gusset skirt side)
total gusset weight = number of gussets x gusset weight
total gusset weld length = number of gussets x gusset weld length
Calculate the total gusset surface area.
gusset open side =
gusset height + gusset base gusset thickness
Calculate the total surface area by multiplying by the number of gussets.

total gusset surface area = number of gussets x (2 x gusset face area + gusset open side)
Single Base Ring With External Chairs
Coster assumes a rectangular shape for the top plate and that the number of chairs is
equal to the number of bolts.
number of chairs = number of bolts

gusset base = (Base OD - Skirt OD) /2
gusset face area = ((gusset base + compression ring width) / 2 ) x gusset height
Calculate the gusset skirt side to consider the extra length for a flared skirt (for a straight
gusset skirt side = gusset height x cos (skirt angle)
one gusset.
gusset weld length = 2 x (gusset base + gusset skirt side + compression ring width)
In calculating the top chair length, Coster assumes that the overhang is equal to the
gusset thickness for welding purposes.
top chair length = gusset inside separation + 4 x gusset thickness
top chair thickness = compression plate thickness

top chair volume = compression ring width x top chair length x top chair thickness
top chair weight = top chair volume x material density
top chair weld length = top chair length + gusset inside separation
total gusset weight = number of gussets x gusset weight + top chair weight x number of
chairs
toal gusset weld length = number of gussets x gusset weld length + top chair weld length
x number of chairs
gusset open side =
( gusset base top chair width ) + gusset height
total gusset surface area = number of chairs ( ( 4 gusset face area )

+ 2 ( gusset open side gusset thickness + top chair width top chair length ) )
Double Base Ring
Calculate the base ring entry on the estimate following the formulas below which
determine the gusset information. Repeat the skirt base ring calculations section for the
compression ring entry on the estimate following the single base ring with no gussets
formulas and substituting the compression ring dimensions in place of the base ring
dimensions.
gusset base = (Base OD - Skirt OD) / 2
gusset face area = (( gusset base + compression ring width) /2) x gusset height
Calculate the gusset skirt side to consider the extra height for a flared skirt (for a straight
gusset skirt side = gusset height x cos (skirt angle)
one gusset.
gusset weld length = 2 x (gusset base + gusset skirt side + compression ring width)
total gusset weight = number of gussets x gusset weight
total gusset weld length = number of gussets x gusset weld length
total gusset surface area = number of gussets x (2 x gusset face area)
Centered Bolting Chair
number of chairs = number of bolts

chair base = (Base OD - Base ID) / 2
inside arc radius = gusset inside separation /2
outside height = gusset height + gusset thickness
outside width = gusset inside separation + 2 x gusset thickness
outside arc radius = outside width /2
Calculate the chair volume and the chair to skirt weld length.
arc length = ( x inside arc radius) / 2
arc volume = arc length x gusset thickness x chair base
straight length = gusset height - inside arc radius
straight length = gusset height - inside arc radius
straight volume = straight length x gusset thickness x chair base
chair volume = (arc volume + straight volume) x 2
chair to skirt weld length = (arc length + straight length) x 2
Calculate the chair weight and chair weld length based on the chair volume and chair to
skirt weld length calculated above. The chair weld length is multiplied by two to include
welding on both sides.
chair weight = chair volume x material density
chair weld length = 4 x chair base + chair to skirt weld length x 2
total gusset weight = number of chairs x chair weight
total gusset weld length = number of chairs x chair weld length
total gusset surface area = number of chairs x (2 (chair to skirt weld length x chair base)
+ 2 x (chair to skirt weld length x gusset thickness))
Single Base Ring With No Gussets
total gusset weight = 0

total gusset weld length = 0
total gusset surface area = 0
The total gusset weight, total gusset weld length, and total gusset surface area have now been
calculated according to the base ring configuration.
Base Ring Calculations For All Ring Configurations
Calculate the total base ring weight.

total base ring weight = base ring weight + total gusset weight
Coster determines the gusset fillet weld size as the minimum of the gusset thickness and the skirt
thickness.
gusset fillet weld size = minimum (gusset thickness or skirt thickness)
gusset weld area = gusset fillet weld size 2 / 2
Calculate the base ring weld area. Coster determines the base ring fillet weld size as the minimum
of the base ring thickness and the skirt thickness.
base ring fillet weld size = minimum (base plate thickness or skirt thickness)
base ring weld area = base ring fillet weld size 2 / 2
Read the cutting rate from the Miscellaneous Fabrication Labor table based on the base plate
thickness and metallurgy and calculate the cutting hours.
Read the fillet welding rate from the Miscellaneous Fabrication Labor table based on the fillet weld
size and metallurgy and calculate the fillet weld length and fillet welding hours.
fillet weld length = x 2 x (Skirt ID + (2 x skirt thickness))
fillet weld hrs = fillet weld rate x (fillet weld length / 12)
If the base ring configuration is Single Base Ring No Gussets then the gusset welding hrs is zero.
Otherwise, read the gusset welding rate from the Miscellaneous Fabrication Labor table based on the
gusset thickness and metallurgy and calculate the gusset welding hours.
gusset weld hrs = gusset welding rate x (total gusset weld length /12)
Read the drilling rate from the Miscellaneous Fabrication Labor table based on the base plate
thickness and metallurgy and calculate the drilling hours.
drilling hrs = drilling rate x number of bolts
Calculate the inside radius and base ring width for use in the calculations below.
inside radius = Base ID / 2
base ring width = (Base OD - Base ID) / 2
Calculate the area of the base ring to use when calculating scrap material.
area of base ring = x ((Base OD / 2) 2 - (Base ID /2) 2 )
Calculate the width of the base ring including the waste from flame cutting from the Fabrication
dialog on the Defaults - Other menu.
base ring burn out width = base ring width + waste from flame cutting
Coster makes six groups of calculations to find the total cost (labor and material) of the base ring
based on the number of segments in which the base ring is divided (one segment up to six segments).
Coster chooses the layout of the base ring for the estimate according to the lowest total cost.
a)
One Segment
Calculate the required plate length and required plate width to lay out the base ring using
a rectangular piece of material. If there is only one segment, Coster uses Base OD for
the required dimensions.
required plate length = Base OD
required plate width = plate length
cut length = x (Base ID + Base OD)
cutting hrs = ((cutting length / 12) x cutting rate) / 60)
plate cutting hrs
The groove weld length and groove welding hours are zero.
Read the labor hours to layout the base ring from the Base Plate Layout Labor table
according to the base ring ID and the number of segments (one segment).
Using the required plate length and width calculated, Coster determines suitable plate
size(s) (stock plate width and stock plate length) from which to cut the base ring from the
Stock Plate Sizes table or user defined plate sizes entered (see Plate Selection on page
3-2).
material weight = required plate length x required plate width x base plate thickness x
material density
material cost = material weight x plate cost per lb
welding labor hrs = fillet weld hrs + gusset weld hrs + groove weld hrs
other labor hrs = cutting hrs + layout hrs + drilling hrs
total labor hrs = welding labor hrs + other labor hrs
total labor cost = (welding labor hrs x welding labor rate) + (other labor hrs x
manufacturing labor rate)
total cost = material cost + total labor cost
scrap area = stock plate width x stock plate length - area of base ring
b)
Two Segments to Six Segments
The following calculations will be made for base rings from two to six segments. In the
equations below we will use a variable called segments to represent the number of
segments (2 to 6). To determine the minimum required dimension (length and width) for
a plate containing circular ring segments of a base ring it is easiest to orient the ring with
the vertical x = 0 bisecting one of the ring segments as shown in the figure below with
three ring segments.
By orienting the ring so that one of the segments is bisected by the vertical Coster
calculates the angle theta.
= 90 ( 180 segments )
Calculate the required plate height and width.
x = inside radius cos ( )

y i = inside radius sin ( )
= acos ( x ( inside radius + base ring burn out width ) )
y o = ( inside radius + base ring burn out width ) sin ( )
k = yo yi
b = ( inside radius + base ring burn out width ) y o

required plate length = (segments x k) + b
required plate width = 2 x (inside radius + base ring burn out width) x cos ( )
Calculate the plate cutting length according to the plate dimensions Coster has
determined for each piece required to fabricate the skirt base ring (cutting the stock plate
to the required plate size). Calculate the segment cutting labor to cut out the individual
pieces that make up the skirt base ring.
plate cutting hours = plate cutting length 12 cutting rate 60

segment cutting length = x (Base ID + Base OD) + (2 x segments x base ring width)
segment cutting hours = segment cutting length / 12 x cutting rate / 60
total cutting hours = plate cutting hours + segment cutting hours

Calculate the welding labor.
groove weld length = segments x base ring width
Read the groove welding rate from the Miscellaneous Fabrication Labor table.
groove weld hrs = groove weld rate x (groove weld length / 12)
Read the labor hours to layout the base ring from the Base Plate Layout Labor table
according to the base ring ID and the number of segments (2 to 6).
The required plate dimensions vary according to the number of segments for the skirt
base ring. Coster determines suitable plate size(s) (stock plate width and stock plate
length) from which to cut the base ring from the Stock Plate Sizes table or user defined
plate sizes entered (see Plate Selection on page 3-2).
material weight = required plate length x required plate width x base plate thickness x
material density
material cost = material weight x plate cost per lb
welding labor hrs = fillet weld hrs + gusset weld hrs + groove weld hrs
other labor hrs = cutting hrs + layout hrs + drilling hrs
total labor hrs = welding labor hrs + other labor hrs
total labor cost = (welding labor hrs x welding labor rate) + (other labor hrs x
manufacturing lab rate)
total cost = material cost + total labor cost
scrap area = stock plate width x stock plate length - area of base ring
Calculations After Determining the Number of Segments for the Skirt Base Ring
Coster has determined the number of segments, plate sizes, labor hours, labor costs, and material
costs for the base ring.
base ring weld volume = base ring weld length x base ring weld area
gusset weld volume = total gusset weld length x gusset weld area
Calculate the groove weld area similar to the long seam calculation for a cylinder using the base
thickness and the base OD.
groove weld volume = groove weld length x groove weld area
weld rod weight = (base ring weld volume + gusset weld volume + groove weld volume)
x weld rod density / weld recovery
outside surface area = (base ring surface area + gusset surface area) / 144
Skirt Calculations
Skirts are estimated using the stock plate size(s) that Coster selects to cut out the skirt. Refer to
How Coster Determines The Layout of Conical Sections on page 11-6 (conical skirts) and How
Coster Determines Material Layout and Plate Requirements (Default Method) on page 11-3
(straight skirts) for the methods that Coster uses to select plate sizes. Plate unit cost is read from the
Plate Costs table. Material cost for the skirt is calculated using the finished weight and the plate unit
cost.
The stock plate used for cutting out the skirt is accounted for in the Weight of Source Material
column and in the listing of plate usage in the Bill of Materials. Cutting length is calculated based
on the cutting layout to cut out the required plate size from a larger stock plate. For conical skirts
there is an extra cutting length added to include cutting out each segment required to fabricate the
skirt. The cutting labor rate is read from the Miscellaneous Fabrication Labor table. Forming labor
hours for cylindrical skirts are read from the Cylinder Forming Labor table. Forming labor hours for
conical skirts are read from the Cones and Skirts Forming Labor table.
Other properties (metallurgy, material density, welding rod density, normalization and impact test
premiums) are found on the Material Properties table. Normalization and impact test premiums are
added to the material cost if required (see Normalization and Impact Testing on page 11-93).
Circumferential seam welding and longitudinal seam welding are calculated using the deposition
rate tables (Weld Deposition Rate - Circumferential Seam Weld and Weld Deposition
Rate - Longitudinal Seam Weld) based on the type of welding selected from the Weld Detail dialog
on the Defaults - Welding menu. Blasting/Cleaning is calculated according to the type of blasting
on the Grinding table according to the selections on the User Selectable Items dialog. Labor hours
to fit up the skirt to the attached component are read from the Fitup Labor tables.
-
top inner diameter

top outer diameter
bottom inner diameter
bottom outer diameter
cone angle
weight of the skirt
skirt thickness
length
material used for the skirt
starting elevation
ending elevation
Large ID = Maximum (top outer diameter, bottom outer diameter)

Small ID = Minimum (top outer diameter, bottom outer diameter)
Determine the slant length to use when calculating surface area:
slant length
theta
Large ID
Small ID
slant length =
length
length + ( ( Large ID Small ID ) 2 )
Material Costs
determine metallurgy, material density, weld rod density, and weld rod unit cost.
plate weight = plate length x plate width x plate thickness x plate material density
required to fabricate the skirt and the plate size from which each of these pieces will be
cut (see Plate Selection on page 3-2).
weld rod weight = ( length weld area weld rod density ) weld recovery
weld rod material cost = weld rod weight weld rod cost per lb
Forming Labor
Read forming labor hours for cylindrical skirts from the Cylinder Forming Labor table
and read forming labor hours for conical skirts from the Cones and Skirts Forming Labor
table based on thickness and Large ID
Fitup Labor
The fitup labor hours for skirts are read from the Fitup Labor - Skirt table based on the
thickness and diameter of the top of the skirt.
Cutting Labor
Read the cutting rate based on the skirt thickness and material from the Miscellaneous
Fabrication Labor table. The total cutting length is calculated according to the plate
dimensions Coster has determined for each piece required to fabricate the skirt and the
length to cut out each segment.

total cutting hours = -------------------------------------------------------------------------------12 60

labor hrs = -------------------------------------------------------------------------------------------------------------------weld deposition rate operator weld efficiency
labor cost = labor hrs welding labor rate
Bevelling Labor
a)
Cylindrical Skirts:
The top and bottom bevel lengths are both the "y" dimension of the required plate size(s)
used to fabricate the skirt. The extra bevel length is the "x" dimension of the required
plate size(s) multiplied by 2 so that both sides of the seam are bevelled (this is usually
the longitudinal seam):
extra bevel length = 2 X required plate dimension

For skirts custom cut to component size the extra bevel length is calculated:
extra bevel length = 2 X required plate dimension number of long seams

b)
Conical Skirts
Calculate bevel lengths where:

If the orientation of the skirt from top to bottom is Small to Large calculate the top and
bottom bevel length:
DS
DL
If the orientation of the skirt from top to bottom is Large to Small calculate the top and
bottom bevel length:
DL
DS
The extra bevel length is the slant length multiplied by 2 so that both sides of the seam
are bevelled:
extra bevel length = 2 slant length

Surface Area
0.5 slant length ( Large OD + Small OD )

outside surface area = -----------------------------------------------------------------------------------------------------------------------144
( 0.5 slant length ( Large ID + Small ID ) )
inside surface area = ---------------------------------------------------------------------------------------------------------------------144
Nozzle Calculations
-
nozzle thickness
ID (Nozzle ID)
OD (Nozzle OD)
nozzle material
whether nozzle material is normalized
whether nozzle material is impact tested
nozzle length
nozzle quantity
nozzle weight (includes pad weight)
nozzle tag
nozzle starting elevation
nozzle ending elevation
nozzle inside projection
nozzle configuration
whether it is radial or hillside
orientation angle (radial angle)

tipping angle (tilt angledegrees)
radial distance
whether it is a pipe
pipe schedule -- 5, 10, 20, 30, 40, 60, 80, 100, 120, 140, 160, Std, XST, XXS
pipe nominal size
whether it is a coupling
type of coupling -- 3000#, 6000#
coupling nominal size
description of attached component (shell material, Shell ID, Shell OD, shell
thickness, radiography)
pad material
pad thickness
pad width
whether pad normalized
whether pad impact tested
flange code (ASME B16.5/16.47 or ASME Section VIII Division 1 Appendix 2)
flange type -- welding neck (WN), slip on (SO), threaded (TH), socket weld
(SW), lap joint (LJ), standard long weld neck (LwnST), heavy barrel long weld
neck (LwnHB), full body long weld neck (LwnFB), variable body v1 long weld
neck (LwnV1), variable body v2 long weld neck (LwnV2), variable body v3 long
weld neck (LwnV3), ring type integral, ring type full face gasket, ring type loose,
weld neck integral, slip on full face gasket, slip on loose, slip on integral, lap joint
loose, split loose, reverse integral, reverse loose
class -- no flange, 75#, 150#, 300#, 400#, 600#, 900#, 1500#, 2500#
flange material
flange weight
flange nominal size
flange ID
flange OD
raised face OD
raised face height
number of bolts
bolt diameter
bolt length
bolt material
bolt circle
gasket ID
gasket OD
long weld neck size
whether there is a blind attached
blind weight
pad to nozzle groove weld size (upper groove weld thickness)
nozzle to shell groove weld size (lower groove weld thickness)
inner fillet weld size (inner fillet weld thickness)
outer fillet weld size (outer fillet weld thickness)
lower fillet weld size (lower fillet weld thickness)

-
waste from flame cutting

bevel angle (nozzle groove welds) (nozzle weld angle)
weld gap
Calculate the pad OD.
Pad ID = Nozzle OD
Pad OD = Pad ID + ( 2 Pad Width )
Calculate the pad weight.
2
area of pad = ( ( pad OD 2 ) ( pad ID 2 ) )

pad weight = area of pad pad thickness pad density
Calculate the nozzle weight.
nozzle weight = nozzle weight pad weight

Calculate the lwn weight.
lwn weight = ( nozzle weight pad weight ) + flange weight

Properties and Material Costs
Coster uses the material density, welding rod density, and welding rod cost of the
shell to which the nozzle is attached for all nozzles. Read the Material Properties
table to find the shell metallurgy, shell material density, shell weld rod density and
shell weld rod unit cost of the material to which the nozzle is attached.
Long Weld Neck (lwn)
Read the Material Properties table to find the metallurgy of the long weld neck
flange material.
lwn length = nozzle length

theta = atn ( nozzle OD 2 shell ID 2 )
extra length for radial nozzle = shell ID 2 ( 1 cos ( theta ) )
For nozzle configuration types 1 and 2 adjust the lwn length:
lwn length = lwn length + shell thickness + extra length for radia nozzle
+ flange length
For nozzle configuration types 3 and 4 adjust the lwn length:
lwn length = lwn length + shell thickness + inside projection

+ extra length for radial nozzle + flange length
Pipe
Read the Pipe Cost Schedule table to find the pipe cost per ft based on the pipe
material, pipe schedule and pipe nominal size. Coster will not interpolate values for
Pipe Costs as the costs vary greatly depending upon standard sizes. Read the
Material Properties table to find the metallurgy, normalization premium and impact
testing factors.
Coupling
Read the Coupling Costs table to find the coupling cost based on the coupling
material, type of coupling, and coupling nominal size. Read the Coupling
Installation Labor table to find the installation labor hours based on type of coupling,
vessel thickness and coupling nominal size. Read the Material Properties table to
find the metallurgy, normalization premium and impact testing factors.
Plate
Read the Plate Costs table to find the plate cost based on the plate material, plate
width, and plate thickness. Read the Material Properties table to find the metallurgy,
normalization premium and impact testing factors.
Studded Outlet
Coster asks the user to enter a material cost for the studded outlet which is displayed
in the flange cost column of the estimate. The labor hours to install the studded
outlet are calculated similarly to nozzles using the shell weld rod density to calculate
welding.
Calculate the total nozzle length.
nozzle weight
nozzle cut length = ---------------------------------------------------------------------------------------------------2
2
( Nozzle OD Nozzle ID ) density
---------------------------------------------------------------------------------------------------4
Custom Integral Forging
Coster asks the user to enter a material cost for the custom integral forging.
Installation labor hours are calculated similarly to nozzles using the shell density as
the material density. Flange welding labor hours are zero.
length = total nozzle length from outside edge of vessel to outside end of flange
finished length = length + inside projection + shell thickness

Flange Cost, Flange Labor, Blind Cost, Blind Labor, and Hydrotest Labor
Calculate the material costs and labor based on the type of flange and flange facing (either raised
face (RF) or ring type joint (RTJ). Coster will not interpolate values for Flange Costs as the costs
vary greatly depending upon standard sizes.
1)
No flange attached
flange cost = 0
flange labor = 0
blind cost = 0
blind labor = 0
hydrotest labor = 0
2)
Coupling
flange cost = 0
flange labor = 0
blind cost =0
blind labor = 0
hydrotest labor = 0
3)
Long Weld Neck

Flange Cost and Flange Labor
flange labor = 0
There is a separate long weld neck flange costs table and a separate long weld neck
flange specs table for each flange type. Read the appropriate LWN Flange Costs
table to find the standard length flange cost based on the flange material, class,
flange facing and long weld neck size. Read the appropriate LWN Flange Specs
table to find the standard length and multiplication factor for cost per one inch
lengths (cost per 1 inch length) based on the LWN size. This multiplication factor is
used to calculate the cost of a long weld neck which is shorter or longer than the
standard length.
Coster uses the nozzle OD for calculations. Calculate the long weld neck cost based
on the standard length from the LWN Flange Specs table.
If the long weld neck length is shorter or longer than the standard length, calculate
the cost as shown below.
i) shorter than standard length
cost calculation
long weld neck cost = standard length cost + cutting fee

ii) longer than standard length
cost calculation
Find the next purchased length beginning at 12 inches and incrementing by 2 inch
lengths (12 inches, 14 inches, etc.).
extra length = next purchased length required long weld neck length
extra cost = extra length cost per 1 inch length
long weld neck cost = standard length cost + extra cost + cutting fee
Blind Flange/Hydrotest
If there is a blind attached, then hydrotest labor = 0 and the blind material cost and
blind labor hours are calculated as follows.
Read the Blind Flange Labor table to find the blind labor hours according to the
LWN size and class.
Read the Blind Flange Cost table to find the blind flange cost based on flange
material, class, flange facing and LWN size.
4)

Read the plate cost from the Plate Cost table based on the flange material, flange OD,
and flange thickness.
material cost = plate cost per lb flange weight

5)
All other Flange Types

Flange Cost/Flange Labor
There are flange cost tables for each flange type. Read the appropriate Flange Costs
table to find flange cost based on flange material, class and flange nominal size (for
weld neck flanges the cost is also determined by bore size and flange facing).
There are two flange labor tables - fitup labor and welding labor. Read the
appropriate Flange To Nozzle labor table to find labor hours to fitup and weld the
flange to the nozzle based on the flange type (weld neck flange or other ASME
B16.5/16.47 flange), metallurgy, nozzle OD and pipe schedule. Since these tables do
not consider heavy barrel weld neck flanges, the flange labor for these types is zero.
flange labor hrs = fitup flange labor hrs + welding flange labor hrs
To determine flange labor hours Coster reads an internal table (this table cannot be
viewed in Coster) called Standard Pipe Thickness to find the pipe schedule for the
specified nozzle OD and thickness. This table contains nozzle thickness as a
function of nozzle OD and pipe schedule and the fields in this table match the fields
in the flange labor hours tables. Using this information Coster will determine the
flange fitup and welding labor hours from the fitup and welding flange tables. The
method that Coster uses to calculate flange fitup labor hours for scheduled and
non-scheduled nozzles is shown below.
Scheduled Nozzles
Example: SA 106B Seamless, nozzle ID of 5.761 inches, nozzle thickness of 0.432
inches with a weld neck flange.
Coster reads the Standard Pipe Thickness table to find the corresponding pipe
schedule (Sch 80) for the specified nozzle OD of 6.625 inches and thickness of 0.432
inches.
Using the specified nozzle OD (6.625 inches) and pipe schedule (Sch 80) Coster
reads the flange labor hours (2.1 hours) for a carbon steel (CS) weld neck flange
from the Flange to Nozzle - Fitup Labor table. If the flange fitup labor hours read
from the table are zero or if the record for 6.625 inch nozzle OD has been deleted
from the table then Coster will interpolate a value for the specified nozzle OD within
the pipe schedule field.
Non-Scheduled Nozzles
Example: SA 516 70, nozzle ID of 5.75 inches, nozzle thickness of 0.625 inches
with a weld neck flange
Coster reads the Standard Pipe Thickness table to determine four points to use for
interpolating flange fitup labor hours for the specified nozzle OD and thickness.
Step 1: Coster reads the Standard Pipe Thickness table. Using the specified nozzle
OD (7 inches) and thickness (0.625 inches), Coster finds the closest smaller nozzle
OD (6.625 inches) and the closest smaller thickness (0.562 inches) and closest larger
thickness (0.906 inches) for this smaller nozzle OD.
Using the pipe schedule that corresponds to the smaller thickness (Sch 120) and the
larger thickness (Sch 160) for the smaller nozzle OD, Coster reads the flange fitup
labor hours for a carbon steel (CS) weld neck flange from the Flange to
Nozzle - Fitup Labor table. If either of these labor hours is zero, Coster asks you to
enter the flange fitup labor hours. The flange fitup labor hours read from the fitup
labor table for 6.625 inch nozzle OD are 3.2 hours for Sch 120 and 4.3 hours for Sch
160. Using these fitup labor hours and their corresponding thickness, Coster can
interpolate fitup labor hours for the specified thickness.
Interpolation for 6.625 inch nozzle:
Smaller thickness
0.562 inches
Specified thickness
0.625 inches
Larger thickness
0.906 inches
Flange Fitup Labor Hours

3.2 (read from table)
3.402 (interpolated value)
Step 2: Similar to Step 1 above Coster determines fitup labor hours for the specified
thickness for the larger nozzle OD (8.625 inches).
Using the specified nozzle OD (7 inches) and thickness (0.625 inches), Coster finds
the closest larger nozzle OD (8.625 inches) and the closest smaller thickness (0.593
inches) and closest larger thickness (0.718 inches) for this larger nozzle OD.
Using the pipe schedule that corresponds to the smaller thickness (Sch 100) and the
larger thickness (Sch 120) for the larger nozzle OD, Coster reads the flange fitup
labor hours for a carbon steel (CS) weld neck flange from the Flange to
Nozzle - Fitup Labor table. If either of these labor hours is zero, Coster asks you to
enter the flange fitup labor hours. The flange fitup labor hours read from the fitup
labor table for 8.625 inch nozzle OD are 3.8 hours for Sch 100 and 5.1 hours for Sch
120. Using these fitup labor hours and their corresponding thickness, Coster can
interpolate fitup labor hours for the specified thickness.
Interpolation for 8.625 inch nozzle:
Smaller thickness
0.593 inches
Specified thickness
0.625 inches
Larger thickness
0.718 inches

Now Coster has fitup labor hours for the specified thickness (0.625 inches) for both
the smaller OD (6.625 inches) and larger nozzle OD (8.625 inches).
Step 3: Using these fitup labor hours, Coster can interpolate between the smaller and
larger nozzle OD to find the flange fitup labor hours for the specified nozzle OD and
thickness.
Interpolation for 7 inch nozzle OD:
Smaller OD
6.625 inches

3.402 (interpolated value from above)
Specified OD
Larger OD
7 inches
8.625 inches

4.133 (interpolated value from above)
The flange welding labor hours will be calculated using the same method as the
flange fitup labor hours.
Blind Flange/Hydrotest
If there is a blind attached, then the hydrotest labor = 0 and the blind material cost
and blind labor hours are calculated as follows.
Read the Blind Flange Labor table to find the blind labor hours according to the
flange nominal size and class.
Read the Blind Flange Cost table to find the blind flange cost based on flange
material, class, flange facing and flange nominal size.
Material Cost
Coster does not report a pipe material cost for long weld necks. For couplings the material cost is
the cost that was read from the coupling costs table. For nozzles from plate or pipe material, the
material cost is calculated as follows.
1)
Pipe
Calculate the pipe material waste based on the nozzle cut length.
pipe length = nozzle cut length

The waste factor for pipe is calculated according to the pipe minimum cut length or the
pipe material waste set from the Fabrication dialog on the Defaults - Other menu.
If the pipe length is less than the minimum cut length then Coster increases the pipe
length to the minimum length for estimating. In this case the pipe material waste is not
considered.
If the pipe length is more than the minimum cut length then Coster adds the pipe material
waste for estimating.
pipe material cost = ( ( adjusted pipe length ) 12 ) pipe cost per ft

2)
Plate
Coster uses an internal procedure to determine the plate dimensions needed to form the
nozzle and also the plate size from which the nozzle will be cut (see Plate Selection on
page 3-2).
plate weight = finished weight from Compress

plate material cost = plate weight plate cost per lb
long seam weld area long seam weld length shell weld rod density
long seam labor hrs = -----------------------------------------------------------------------------------------------------------------------------------------------------------------------long seam weld deposition rate operator weld efficiency
Read the forming labor hours from the Cylinder Forming Labor table.
Read the nozzle cutting rate based on the nozzle thickness and metallurgy from the Miscellaneous
Fabrication Labor table. The total nozzle cutting length is calculated according to the plate
dimensions Coster has determined for each piece required to fabricate the nozzle. Read the shell
cutting rate (to cut the hole in the shell for the nozzle) based on the shell thickness and metallurgy.
For radial nozzles the nozzle extra welding length is zero.
total nozzle cutting length nozzle cutting rate

total nozzle cutting hours = ----------------------------------------------------------------------------------------------------------------12 60
cutting length for hole in shell = nozzle OD + extra welding length nozzle
cutting length for hole in shell shell cutting rate
total shell cutting hours = ---------------------------------------------------------------------------------------------------------------------12 60
total cutting hours = total nozzle cutting hours + total shell cutting hours
Read the Nozzle to Shell or Head Labor table for labor hours to attach the nozzle for types other than
coupling (coupling installation labor is read from tables above) based on the shell thickness and
nozzle OD.
Hillside (Nonradial) Nozzles
Coster calculates the extra welding length required for hillside nozzles on cylinders, transitions and
heads to increase the welding labor.
Rs = shell outer radius for cylinder or hemispherical head
= dish radius for F&D head
= transition outer radius at nozzle center line for transition
= head outer radius for 2:1 ellipsoidal head
R s = 0.5 attached component OD

X 1 = nozzle offset nozzle outer radius
X 2 = nozzle offset + nozzle outer radius

Nozzle attached to 2:1 ellipsoidal head
2
Y 1 = 0.5 R s max ( 1 X 1 R s , 0 )
Y 2 = 0.5 R s max ( 1 X 2 R s , 0 )
Nozzle attached to cylinder, transition, F&D head, hemispherical head
Y1 =
max ( R s R s X 1 X 1, 0 )
Y2 =
max ( R s R s X 2 X 2, 0 )
Calculations for all hillside nozzles
chord length =
( X 1 X2 ) + ( Y1 Y2 )
major axis nozzle = chord length 2

minor axis nozzle = nozzle outer radius
Calculate the length of the slot (ellipse perimeter) based on the nozzle major and minor
axes calculated above.
ellipse perimeter nozzle

= 2 minor axis nozzle + 4 ( major axis nozzle minor axis nozzle )
extra welding length nozzle = ellipse perimeter nozzle nozzle OD
If there is a pad present then calculate the extra welding length for the pad.
major axis pad = chord length 2 + pad width

minor axis pad = nozzle outer radius + pad width
Calculate the length of the slot (ellipse perimeter) based on the pad major and minor axes
calculated above.
ellipse perimeter pad = 2 ( minor axis pad + 4 ( major axis pad minor axis pad )
extra welding length pad = ellipse perimeterpad pad OD
Read the Fitup Labor - Nonradial Nozzles table to find the labor multiplication factor based on the
radial angle. This same multiplication factor is used to adjust the pad labor. The nozzle installation
labor hours and pad installation labor hours are multiplied by this nonradial labor factor to account
for extra labor involved for a nonradial nozzle.
nozzle installation labor hours = labor hours nonradial labor factor

pad installation labor hours = labor hours nonradial labor factor
Calculations for tilted nozzles located on a cylinder
radial angle in radians (from Compress)
minor axis nozzle = OD 2

tilt angle radians = tilt angledegrees 180
major axis nozzle = minor axis nozzle cos ( abs ( tilt angle radians ) )
Calculate the length of the slot (ellipse perimeter) based on the nozzle major and minor
axes calculated above.
ellipse perimeter nozzle

= 2 minor axis nozzle + 4 ( major axis nozzle minor axis nozzle )
tilted welding length nozzle = ellipse perimeternozzle
Read the Fitup Labor - Nonradial Nozzles table to find the labor multiplication factor based on the
radial angle. The nozzle installation labor hours are multiplied by this nonradial labor factor to
account for extra labor involved for a tilted nozzle.
nozzle installation labor hours = labor hours nonradial labor factor

If there is a pad present then a multiplication factor is calculated to add extra labor hours for cutting
and welding of the pad. The multiplier is calculated using the tilted nozzle welding length and the
nozzle OD.
pad multiplier for cutting and welding = tilted welding lengthnozzle ( OD )
Pad Calculations
If there is a pad present calculate the following. Nozzle configurations 1, 3, 5, 6, 7 do not have a
pad. Nozzle configurations 2, 4, 8 have a pad.
Coster uses the metallurgy, material density, welding rod density, and welding rod cost of the shell to
which the nozzle is attached for pads. Read the Material Properties table to find the shell metallurgy,
shell material density, shell weld rod density and shell weld rod unit cost of the material to which the
nozzle and pad are attached.
Read the Plate Costs table to find the pad plate cost. Read the Material Properties table to find pad
normalization premium and pad impact testing factors.
Read the Pad to Nozzle Labor table to find the labor hours to attach the pad to the nozzle based on
the pad thickness and nozzle OD. The pad installation labor hours are adjusted for nonradial nozzles
based on the nonradial nozzle labor factor. This is the same factor from the Fitup Labor - Nonradial
Nozzles table that Coster looked up for the nozzle. For radial nozzles the nonradial nozzle labor
factor is one.
pad installation labor hours = labor hours nonradial nozzle labor factor
Read the pad cutting rate from the Miscellaneous Fabrication Labor table based on the pad thickness
and metallurgy.
Calculate the pad cutting length (cutting around the outside and inside of the pad). Coster assumes
that there is a plate available for cutting out the pad so Coster does not include cutting out the plate
from a larger piece of stock. For radial nozzles the nozzle extra welding length and pad extra
welding length are both zero.
pad cutting length = ( pad OD ) + ( pad ID )

+ extra welding length nozzle + extra welding length pad
pad cutting length pad cutting rate
pad cutting hours = --------------------------------------------------------------------------------------12 60
Calculate the pad material cost.
pad weight = finished weight from Compress

pad material cost = pad weight pad plate cost per lb
Calculate the plate size required from which to cut out the pad.
pad plate width = nozzle OD + 2 pad width
shell radius = shell OD 2

Calculate the pad plate length for hillside or radial nozzles as follows if the nozzle is
attached to a cylinder, transition, 2:1 ellipsoidal head, F&D head, hemispherical head.
The calculation for F&D heads is an approximation because the knuckle radius is not
considered. Calculate the pad plate length for radial nozzles as follows if the nozzle is
attached to another nozzle (nozzles attached to another nozzle cannot be hillside).
Hillside Nozzles
pad plate length = 2 ( pad width + shell radius asin ( major axis shell radius ) )
Radial Nozzles
pad plate length = 2 ( pad width + shell radius asin ( nozzle OD shell OD ) )
Nozzle Weld Calculations
Calculate the nozzle welding hours based on the weld types available according to nozzle
configuration. For radial nozzles the nozzle extra welding length and pad extra welding length are
both zero.
Configuration
Type 1 (no pad)
Type 2 (with pad)
Type 3 (no pad)
Type 4 (with pad)
Type 5 (no pad)
Type 6 (no pad)
Type 7 (no pad)
Type 8 (with pad)
Weld Types
lower groove weld, inner fillet weld
upper groove weld, lower groove weld, inner fillet weld, outer fillet weld
lower groove weld, inner fillet weld, lower fillet weld
upper groove weld, lower groove weld, inner fillet weld, outer fillet weld,
lower fillet weld
inner fillet weld
lower groove weld, inner fillet weld
inner fillet weld
inner fillet weld, outer fillet weld
Groove weld areas are calculated as follows:

2
Area A = 0.5 groove size tan ( nozzle weld angle )

For nozzle configuration 6 there is no weld gap considered. Therefore Area B = 0
For all other nozzle configurations calculate Area B.
Area B = weld gap groove size

nozzle v groove weld = Area A + Area B
= nozzle bevel angle
Calculate the pad to nozzle groove weld area (upper groove weld area) using the above method
based on pad thickness, upper groove weld thickness, and nozzle configuration.
Calculate the nozzle to shell groove weld area (lower groove weld area) using the above method
based on shell thickness, lower groove weld thickness, and nozzle configuration.
Calculate the inner fillet weld area, outer fillet weld area, and lower fillet weld area.
2
fillet weld area = fillet weld thickness 2

Set the hub diameter equal to the Pad OD for calculations of nozzle configuration 6.
Calculate the pad to nozzle groove weld volume (upper groove weld volume).
upper groove weld volume

= upper groove weld area ( nozzle OD + extra welding length nozzle )
Configuration 6 calculations
lower groove weld volume = lower groove weld area nozzle ID

inner fillet weld volume = inner fillet weld area hub diameter
Configuration 1, 2, 3, 4, 5, 7, 8, 9, 10 calculations
inner fillet weld volume

= inner fillet weld area ( nozzle OD + extra welding length nozzle )
lower groove weld volume
= lower groove weld area ( nozzle OD + extra welding length nozzle )
Calculations for all nozzle configurations
outer fillet weld volume

= outer fillet weld area ( PadOD + extra welding length pad )
lower fillet weld volume
= lower fillet weld area ( nozzle OD + extra welding length nozzle )
total weld volume = upper groove weld volume + lower groove weld volume
+ inner fillet weld volume + outer fillet weld volume + lower fillet weld volume
For groove welds read the Weld Deposition Rate - Nozzle Groove Weld table to find the deposition
rate based on metallurgy, weld thickness and nozzle OD. For fillet welds read the Weld Deposition
Rate - Nozzle Fillet Weld table to find the deposition rate based on metallurgy, weld leg size and
nozzle OD (for the outer fillet weld Coster uses the Pad OD and metallurgy instead of the nozzle OD
and metallurgy to find the deposition rate).
Calculate the welding labor hours for each type of weld using the welding rod density of the shell
material for welding the nozzle and pad.
welding labor hrs = weld volume shell weld rod density

Weld length for x-ray purposes is considered only for a welding neck flange with a nozzle OD
greater than 10.75 inches or for nozzle wall thickness greater than 1.125 inches and for nozzle
groove welds. The number of nozzles is also reported on the x-ray dialog as a guide when spot x-ray
is selected.
total nozzle weld length = nozzle OD

For each pad to nozzle groove weld or nozzle to shell groove weld calculate the weld length and add
together to find the total nozzle groove weld length for x-ray purposes.
x-ray nozzle groove weld length

= x-ray nozzle groove weld length + ( nozzle OD )
total nozzle weld length = total nozzle weld length + x-ray nozzle groove weld length
Calculate the nozzle and pad installation labor cost, flange labor cost, blind labor cost and forming
labor cost using the manufacturing labor rate. Calculate the long seam, flange, nozzle and pad
welding labor costs using the welding labor rate.
labor cost = labor hrs manufacturing labor rate

weld rod weight = ( total weld volume + long seam volume )
shell weld rod density weld recovery
weld rod material cost = weld rod weight shell weld rod cost per lb
ASME Section VIII Division 1 Appendix 2 flange labor:
Read the machining labor hours from the Machining Labor table based on flange
Read the drilling per minute rate from the Drilling Labor table based on flange
material and bolt nominal size.
drilling labor hours = drilling per minute rate flange thickness 60

number of bolts
ASME Section VIII Division 1 Appendix 2 flange welding:
Ring Type Integral
no circumfrential butt weld present
groove weld length = ( flange ID + groove weld size )

Slip On Integral
no cirumferential butt weld present
groove weld length = ( flange ID + hub thickness, G0 groove weld size )

upper fillet weld length = ( flange ID + upper fillet weld size )
lower fillet weld length = ( flange ID + hub thickness, G0
lower fillet weld size )
Calculate the total weld length for ring type integral and slip on integral flange:
total weld length = groove weld length + upper fillet weld length
+ lower fillet weld length
Fabrication Labor table based on metallurgy and weld size to calculate the upper
fillet weld, lower fillet weld and groove weld hours for ring type integral and slip on
integral flange:

groove weld hours = groove weld rate ( groove weld length 12 )
2
groove weld area = ( groove weld size ) 2

2

2

flange welding rod weight = ( groove weld volume + upper fillet weld volume
Ring Type Full Face Gasket, Ring Type Loose, Slip On Full Face Gasket, Slip On
Loose
no circumferential butt weld present

2

2

flange welding rod weight = ( upper fillet weld volume
Calculate the total weld length for ring type full face gasket, ring type loose, slip on
full face gasket and slip on loose flange.
total weld length = upper fillet weld length + lower fillet weld length
Read the fillet welding rate from the Miscellaneous Fabrication Labor table based on
metallurgy and weld size to calculate the upper fillet weld and lower fillet weld hours
for ring type full face gasket, ring type loose, slip on full face gasket and slip on
loose flange:

Weld Neck Integral
circumferential seam weld length = ( flange ID + hub thickness, G0 )

flange ID and hub thickness, G0.
Reverse Integral
circumferential seam weld length = ( flange OD hub thickness, G0 )

Reverse Loose
circumferential seam weld length = ( flange OD + hub thickness, G0 )

Read the circumfential weld deposition rate from the Welding
Time - Circumferential Seam Weld table based on the hub thickness, G0, weld type
and metallurgy.
circumferential seam volume = circumferential seam area

circumferential seam weld length
Calculate welding rod weight as follows:
flange welding rod weight = circumferential seam volume

Lap Joint Loose, Split Loose
There is no welding at all unless a welded lap is specified. If it is a welded lap then
the following welds are present:
groove weld length = flange ID

2
groove weld area = ( lap thickness ) 2

fillet weld length = flange ID
total weld length = groove weld length + fillet weld length

2
upper fillet weld area = ( lap thickness ) 2

upper fillet weld volume = upper fillet weld area fillet weld length
flange welding rod weight = ( groove weld volume + upper fillet weld volume )
Read the fillet welding rate based on metallurgy and lap fillet weld size and the
groove welding rate based on metallurgy and lap thickness from the Miscellaneous
Fabrication Labor table to calculate the fillet weld and groove weld hours for lap
joint loose and split loose flange:
weld hours = weld rate ( weld length 12 )

Leg Calculations
The fillet weld size for welding the legs to the shell and and base plate is determined from the .xml
file. If this value is zero then Coster assumes a fillet weld size of 0.375 inches. This weld size is
also used to look up the base plate fillet weld rate from the Miscellaneous Fabrication Labor table.
The fillet weld size for welding the pad to the shell is also determined from the .xml file. If this
value is zero then Coster assumes a fillet weld size of 0.375 inches.
Leg section width and Leg section length always refer to the same dimension no matter which way
the wide flange is attached to the vessel.
Determine the leg major dimension by using the larger of the Leg section width and the Leg section
length. Similarly determine the base plate and pad major dimensions by comparing the width and
length of each.
The leg material cost is determined by the structural cost per lb read from the Structures/Rings/Tray
Supports Material Cost table based on the leg material, type and size. Find the metallurgy, welding
rod density, and welding rod unit cost from the Material Properties table for the vessel material and
the leg material.
Look up the labor hours for layout and fitup for the pad and base plate on the Legs Labor - Pad and
Legs Labor - Base Plate tables based on the pad major dimension and base plate major dimension.
Also look up the labor hours to layout/burn, fitup, and weld the legs based on the leg major
dimension.
Use the pad material welding rod density and pad material welding rod unit cost to calculate weld
rod weight and weld rod cost to attach the legs to the pad. Use the vessel material welding rod
density and vessel material welding rod unit cost to calculate weld rod weight and weld rod cost to
attach the legs to the vessel.
If the base plate is present Coster assumes the material for the leg base plate to be SA 36. Read the
base plate material unit cost from the Plate Costs table and read the base plate metallurgy, material
density, welding rod density, and welding rod unit cost from the Material Properties table. The base
plate weight is the finished weight but the base plate material cost is calculated to include waste
from flame cutting on all sides of the base plate. Find the cutting rate and drilling labor for the legs
from the Miscellaneous Fabrication Labor table based on the base plate thickness and metallurgy.
The fillet welding rate is also read from the Miscellaneous Fabrication Labor table and the welding
rod weight and welding rod cost to attach the legs to the base plate is calculated using the base plate
welding rod density and welding rod unit cost.
The pad welding is calculated similarly. Coster assumes the material to be SA 36 for the leg pad.
-
Leg overall length
Leg base to girth weld seam length

Leg weight (total of all legs including the base plate weight and pad weight)
Number of legs
Leg section width
Leg section length
Base plate length
Base plate width
Base plate thickness
whether or not a pad is present
Pad length
Pad width
Pad thickness
Leg structural type
Size (if leg type is pipe then size includes pipe schedule)
Leg fillet weld size
Pad fillet weld size
Number of bolts per leg
Vessel material of the component to which the legs are attached
Coster assumes the following for estimating legs:

-
Base plate material = SA 36

Pad material = SA 36
If the leg fillet weld size from the .xml file is zero then the leg fillet weld size is
set to 0.375 inches.
If the pad fillet weld size from the .xml file is zero then the pad fillet weld size is
set to 0.375 inches.
Legs
Read the Material Properties table to determine normalization and impact testing factors. Read the
Structures/Rings/Tray Supports Material Costs table to find the leg cost per lb based on the leg
material, structural type and size.
If leg type is pipe then:
pipe OD = leg section width

Calculate the weight per leg:
weight per leg = ( leg weight number of legs ) base plate weight pad weight
leg material cost per ft = leg cost per lb weight per leg ( leg overall length 12 )
leg material cost = ( leg overall length 12 ) leg material cost per ft
Read the Legs Labor table to find the layout/burn hours, fitup hours and welding hours based on the
leg major dimension.
layout/burn labor cost = layout/burn labor hours manufacturing labor rate

fitup labor cost = fitup labor hours manufacturing labor rate
welding labor cost = welding labor hours welding labor rate
The leg labor hours are displayed as an equation (shown below) in the Fabrication labor hours
column of the Coster estimate.
fabrication labor hours = ( layout hours + fitup hours ) leg quantity

The leg welding labor hours are displayed as an equation (shown below) in the Finishing labor hours
column of the Coster estimate.
finishing labor hours = ( leg to vessel or pad welding hours

+ leg to base plate welding hours ) leg quantity
Weld Rod Calculations
Calculate leg weld length according to the leg structural type.

a)
equal leg angle, leg in
leg weld length = ( ( leg overall length leg base to girth weld seam length ) 2 )
+ 2 leg section length
b)
equal leg angle, leg out or wide flange, flange in
+ leg section length
c)
wide flange, flange out
+ ( leg section width 2 )
Calculate the leg fillet weld volume
2
leg fillet weld volume = leg fillet weld size 2 leg weld length
Read the Material Properties table to determine metallurgy, weld rod density and weld rod unit cost
based on the vessel material to which the legs are attached.
To calculate the weld rod weight, Coster uses the pad weld rod density and pad weld rod unit cost if
the leg is welded to the pad. If the leg is welded to the vessel Coster uses the vessel weld rod density
and the vessel weld rod unit cost.
leg weld rod weight = leg fillet weld volume weld rod density
leg weld rod cost = leg weld rod weight weld rod cost per lb
Calculate the leg to base plate weld length based on the leg structural type.
a)
equal leg angle, leg in, equal leg angle, leg out, wide flange, flange in, and wide
flange, flange out (multiply each section by 2 to weld the inside and outside of the
leg
leg to base plate weld length = ( leg section width 2 ) + ( leg section length 2 )
b)
user defined -- You are asked to enter the "user defined leg width" where it
attaches to the base plate. Coster assumes that the weld length is a square based
on this user defined leg width.
leg to base plate weld length = user defined leg width 4

c)
pipe
leg to base plate weld length = pipe OD

Calculate weld rod weight and weld rod cost based on the weld rod density and weld rod unit cost of
the base plate material.
leg to base plate fillet weld volume

2
= ( base plate fillet weld size 2 ) leg to base plate weld length
leg to base plate weld rod weight
= leg to base plate fillet weld volume base plate weld rod density
leg to base plate weld rod cost
= leg to base plate weld rod weight base plate weld rod unit cost
Base Plate
Read the Plate Costs table to determine plate cost. Read the Material Properties table to determine
metallurgy, material density, normalization and impact testing factors.
Read the Legs Labor - Base Plate table to find the layout hours and fitup hours based on the base
plate major dimension.
layout labor cost = layout labor hours manufacturing labor rate

fitup labor cost = fitup labor hours manufacturing labor rate
Calculate the base plate weight including waste. Add waste from flame cutting to the material
dimensions. This weight will be used to calculate material cost and is the weight displayed in the
Bill Of Materials. Coster also calculates the actual base plate weight which is displayed in the
weight column of the Vessel Detail Cost.
base plate weight including waste

= ( base plate length + ( 2 waste from flame cutting ) )
( base plate width + ( 2 waste from flame cutting ) ) base plate thickness
base plate material density
actual base plate weight = base plate length base plate width
base plate thickness base plate density
base plate material cost = base plate weight including waste base plate cost per lb
Read the Miscellaneous Fabrication Labor table to find the cutting rate and drilling hours based on
the base plate thickness and metallurgy.
base plate cutting length = ( base plate length + base plate width ) 2
base plate cutting hrs = ( ( base plate cutting length 12 )
base plate cutting rate ) 60 )
base plate drilling hrs = drilling hrs number of bolts per leg
Welding of the leg to the base plate is included with the legs.
Pad
Read the Plate Costs table to determine plate cost. Read the Material Properties table to determine
metallurgy, material density, weld rod density, weld rod unit cost, normalization and impact testing
factors.
Read the Legs Labor - Pad table to find the layout hours and fitup hours based on the pad major
dimension.
layout labor cost = layout labor hrs manufacturing labor rate

fitup labor cost = fitup labor hrs manufacturing labor rate
Calculate the pad weight including waste. Add waste from flame cutting to the material dimensions.
This weight will be used to calculate material cost and is the weight displayed in the Bill Of
Materials. Coster also calculates the actual pad weight which is displayed in the weight column of
the Vessel Detail Cost.
pad weight including waste = ( pad length + ( 2 waste from flame cutting ) )
( pad width + ( 2 waste from flame cutting ) ) pad thickness
pad material density
actual pad weight = pad length pad width pad thickness pad material density
pad material cost = pad weight including waste pad material cost per lb
Read the Miscellaneous Fabrication Labor table to find the cutting rate based on the pad thickness
and pad metallurgy, and the fillet welding rate based on the pad fillet weld size and pad metallurgy.
pad cutting length = ( pad length + pad width ) 2

pad cutting hrs = ( ( pad cutting length 12 ) pad cutting rate ) 60 )
Calculate the pad to vessel welding hours.
pad weld length = pad cutting length

pad to vessel welding hrs = pad fillet welding rate ( pad weld length 12 )
Calculate weld rod weight and weld rod cost based on the weld rod density and weld rod unit cost of
the vessel material.
2
pad fillet weld volume = ( pad fillet weld size 2 ) pad weld length
pad weld rod weight = pad fillet weld volume vessel weld rod density
pad weld rod cost = pad weld rod weight vessel weld rod cost per lb
Normalization and Impact Testing
Normalization premium and impact testing are not considered for estimating trays, skirts and skirt
base rings. Normalization and impact testing factors are applied to the material cost if they are
specified for cylinders (made from pipe, fabricated, or purchased), transitions, skirts, vacuum rings,
heads (flat welded or formed), nozzles, and pads. These extra costs are displayed on the estimate as
part of the material cost equation as follows:
total material cost = material cost + ( material cost normalization percent )

+ ( material cost impact testing percent )
Heads
If the head costs are read or interpolated from the corresponding head cost tables then the
equation on the estimate shows the normalization and/or impact testing percentages
added to the head cost. If, however, the head cost is manually entered while costing the
vessel then we assume that the head cost entered already includes extra costs for
normalization and/or impact testing and therefore these percentages are not reflected in
the equation for head material cost on the estimate.
Cylinders
Fabricated cylinders or cylinders made from pipe material will include normalization
and/or impact testing factors in the equation on the estimate. For purchased cylinders
extra costs for normalization and/or impact testing will be added to the equation on the
estimate if the cylinder costs are read or interpolated from the cylinder costs tables. If
the user manually enters the cylinder cost while costing the vessel then we assume that
the cost entered includes any extra costs for normalization and/or impact testing so these
extra percentages are not reflected in the equation for cylinder material cost on the
estimate.
Nozzles
Nozzles made from pipe material do not add extra costs for normalization and/or impact
testing. Fabricated nozzles add extra costs for normalization and/or impact testing into
the equation on the estimate. If the user manually enters the nozzle cost while costing
the vessel then we assume that the cost entered includes any extra costs for
normalization and/or impact testing so these extra percentages are not reflected in the
equation for nozzle material cost on the estimate.
ASME B16.5/16.47 Body Flanges
We assume that normalization and impact testing factors have already been included in
these costs according to the material specification so these extra percentages are not
reflected in the equation for ASME B16.5/16.47 and ASME Section VIII Division 1
Appendix 2 body flange material costs on the estimate.
Davit Calculations
If the "Always Add Davits" box is checked then davits will be considered for manway
openings with a manway nominal size greater than or equal to the "Minimum Manway
Diameter Required to Add Davits" value. The manway nominal size and the class are
used to look up the cost, labor, and weight of the davit from the corresponding davit
table. To determine the manway nominal size Coster uses the pipe nominal size (pipe
material) or the inner diameter (fabricated nozzle) of the manway and compares this size
to the manway diameters listed on the davit table. Coster selects the manway diameter
from the davit table which is equal to or larger than the pipe nominal size or inner
diameter (if the pipe nominal size or inner diameter lies within the range of manway
diameters listed on the table) and uses this manway nominal size to determine the davit
cost, labor, and weight. Davits are listed separately in the Miscellaneous section of the
estimate and the weight of each davit is listed in the Bill of Materials.
Grinding Calculations
Grinding is calculated according to the selections on the User Selectable Items dialog for
cylinders, transitions, heads, skirt base rings, and skirts. For skirt base rings the groove
weld length calculated for grinding is multiplied by two to include smooth grinding on
both the top and bottom of the groove weld (the base ring weld length and total gusset
weld length are not considered for grinding because they are fillet welds which do not
require grinding). The grinding rates are read from the Grinding Labor table based on
metallurgy, thickness, and type of grinding (normal, flush, smooth). The inside and
outside grinding rates are calculated and combined for a total grinding rate. Grinding is
not considered for ASME B16.5/16.47 and ASME Section VIII Division 1 Appendix 2
body flanges.
inside grinding rate = grinding rate

outside grinding rate = grinding rate
total grinding rate = inside grinding rate + outside grinding rate
grinding labor hrs = total weld length 12 total grinding rate
grinding labor cost = grinding labor hrs manufacturing labor rate
Blasting/Cleaning Calculations
Blasting/Cleaning is calculated based on the selection on the User Selectable Items dialog for
cylinders, transitions, heads, skirt base rings, skirts (blasting/cleaning is always calculated for both
the inside and outside of the skirts if blasting/cleaning is selected), and saddles. Blasting/Cleaning is
not considered for ASME B16.5/16.47 and ASME Section VIII Division 1 Appendix 2 body
flanges. If the method chosen is "wire brush" then the labor hours will be displayed under the
"cleaning labor" column on the estimate. All other methods chosen will be displayed under the
"blasting labor" column on the estimate.
blasting/cleaning labor hrs = ( outside surface area 100 ) blasting hrs per 100 sq ft
blasting/cleaning labor cost = blasting/cleaning labor hrs blasting labor cost per hr
Paint/Primer Calculations
Paint and primer type, quantities, labor hours, and labor costs are calculated according to the
selections on the User Selectable Items dialog for cylinders, transitions, heads, skirt base rings, skirts
(paint/primer is always calculated for both the inside and outside of the skirts if paint/primer is
selected), and saddles. Cylinders, transitions, and heads use the inside surface area in the equations
below to calculate painting and priming on the inside of these components. Paint and primer are not
considered for ASME B16.5/16.47 and ASME Section VIII Division 1 Appendix 2 body flanges.
Coverage per 100 sq ft, cost per container, application labor hrs and standard container size are read
from the Paint or Primer database tables according to the paint/primer type selected. Labor cost per
hr is read from the Labor Rates dialog on the Defaults - Other menu.
quantity = ( outside surface area 100 ) coverage per 100 sq ft number of coats
material cost = quantity cost per container
labor hrs = ( outside surface area 100 ) application labor hrs number of coats
labor cost = labor hrs labor cost per hr
Hydrotest Calculations
Coster calculates hydrotest at the end of the costing procedure using the formula from
the Hydrotest dialog on the Defaults - Hydrotest menu for cylinders, transitions, 2:1
ellipsoidal heads, F&D heads, and hemispherical heads. Hydrotest hours are reported in
the miscellanous section of the estimate. The diameter value in this formula is a
weighted average calculated as follows. For transitions Coster calculates an average ID
to replace ID in the formula below. For heads Coster calculates a hydrotest length to
replace the length in the formula below. In addition to these hydrotest hours, Coster
calculates hydrotest hours nozzles when no blind flange is attached (if a blind is attached
then hydrotest hours are zero). To calculate hydrotest hours for nozzles read the blind
labor hours from the Blind Labor table based on the class and the flange nominal size or
long weld neck size. Multiply these blind labor hours by two to determine the hydrotest
hours. Coster estimates the hydrotest hours as the labor hours to attach and remove a
blind. At this time Coster does not take into consideration the cost of water to fill the
tank or the drying time. Coster does not consider hydrotest for ASME B16.5/16.47 or
ASME Section VIII Division 1 Appendix 2 body flanges.
ID weighted average = ( ID length ) total length

Hydrotest Length for Heads (2:1 ellipsoidal, F&D, Hemispherical)
The length of a head for hydrotest purposes is calculated through a comparison of the
head volume compared to the length of a cylinder with an equal volume.
volume of cylinder = ( 4 ) cylinder length ID
Convert the head volume from US gallons to cubic inches
cubic inches head volume = US gal head volume 231

hydrotest length = cubic inches head volume ( 4 ) ID
To turn off hydrotest calculations, set each of the Hydrotest Factors a, b, and c on the
Hydrotest dialog of the Defaults menu to zero.
Post Weld Heat Treatment (PWHT)

If Post Weld Heat Treatment (PWHT) is required on this vessel for any component(s) an
entry for PWHT will be shown on the estimate. Coster determines that "global" PWHT
is required if the following components all require PWHT -- ASME B16.5/16.47 body
flange ASME Section VIII Division 1 Appendix 2 body flange, 2:1 head, f&d head,
hemi head, flat welded head, transition, cylinder. Otherwise if PWHT is required on
some but not all of these components then Coster determines that "local" PWHT is
required. If global PWHT is determined then Coster will also add the weight of the
saddles, skirt base ring and compression ring, legs (including leg base plate and leg pad),
skirts, and vacuum rings to the weight of the welded components. If the ASME B16.5/
16.47 or ASME Section VIII Division 1 Appendix 2 body flange requires PWHT then
the blind weight will be added to the weight of the welded components. Similarly the
weight of the pad will be added if the nozzle to which it is attached requires PWHT.
Global PWHT is calculated by multiplying the weight of the welded components by the
cost per 100 lb user-defined default from the Fabrication dialog on the Defaults - Other
menu. The total PWHT and the weight of the welded components will be displayed on
the estimate. If local PWHT is required you will be asked to enter a total cost for PWHT
during the estimating process. The weight will not be displayed on the estimate for local
PWHT.
X-Ray Calculations
Coster keeps track of the weld lengths for the x-ray dialog according to the weld type
and radiography specified on the vessel for cylinders, transitions, heads, and nozzles.
X-ray is not considered for estimating skirts.
Welding Calculations
One feature of Coster is the ability to automatically switch from single side welding to double side
according to the thickness of the component. The "as-shipped" thickness default is set to
0.75 inches on the Weld Detail dialog of the Defaults - Welding menu. This means that if you have
specified V welding for estimating, Coster forces all components with a thickness less than or equal
to 0.75 inches to be calculated using single V welding and all components with a thickness greater
than 0.75 inches to be calculated using double V welding. Enter a value in the thickness default
input box labelled "Use single weld <= thickness Use double weld > thickness" according to the
type of welding you require. If you would like all components to use a single V weld then select V
welding and set the thickness default to a very large thickness. To force all welding to be double V
select V welding and set the thickness default to zero. This feature operates similarly when U
welding is selected.
APPENDIX A
12
APPENDIX A
Coster Database Tables

Coster uses libraries of cost and other data to calculate an estimate. These libraries are stored as
database tables and the final cost estimate is produced in an Excel-compatible format. Some tables
include abbreviations which used by Coster for metallurgy:
-
CS = Carbon Steel
SS = Stainless Steel
AL = Aluminum
Cu = Copper
Cu Alloy = Cooper Alloy
Ni = Nickel
Ni Alloy = Nickel Alloy
Ti = Titanium
UHT = UHT (ferritic steels with properties enhanced by heat treatment)
Zi = Zirconium
The following is a summary of the database tables provided with your Coster program:
Base Plate Layout Labor -- labor hours to install (layout/fitup) skirt base plate as a
function of base plate ID and the number of ring segments.
Blind Flange Labor -- labor hours to attach a blind flange as a function of class
and flange size. These hours (multiplied by 2) are used to calculate the hydrotest
labor hours for nozzles.
Cones and Skirts Forming -- labor hours to form cones/conical skirts as a function
of cone/conical skirt thickness and large end ID.
Coupling Costs -- pricing for 3000# and 6000# couplings as a function of
coupling material and coupling nominal size .
Coupling Installation Labor -- labor hours (layout/fitup) to install 3000# and
6000# couplings as a function of vessel thickness and coupling nominal size.
Cylinder Costs (formed/tacked) -- pricing for cylinders (formed and tacked) as a
function of material, length, thickness, and OD.
Cylinder Costs (welded) -- pricing for cylinders (formed, tacked, and welded) as a
function of material, length, thickness, and OD.
Cylinder Forming Labor -- labor hours to form cylinders/cylindrical skirts as a
function of cylinder/cylindrical skirt thickness and ID.
Davit Cost -- material cost as a function of manway diameter and class.
< APPENDIX A 12 - 1 >
APPENDIX A
Davit Labor -- labor hours as a function of manway diameter and class.

Davit Weight -- davit weight as a function of manway diameter and class.
Drilling -- drilling labor for appendix 2 flanges as a function of material and bolt
nominal size.
Fitup Labor (cylinder/cylinder) -- labor hours to fit up cylinder to cylinder as a
function of cylinder thickness and cylinder OD (if the OD is not the same for both
cylinders then use the thickness and OD of the cylinder with the larger OD).
Fitup Labor (cylinder/transition) -- labor hours to fit up cylinder to transition as a
function of cylinder thickness and cylinder OD.
Fitup Labor (head/cylinder) -- labor hours to fit up head to cylinder as a function
of cylinder thickness and cylinder OD. This includes formed heads and flat
welded heads sketch (b-1), (b-2), (d).
Fitup Labor (nonradial nozzles) -- fitup labor multiplication factor as a function
of radial angle.
Fitup Labor (skirt) -- fitup labor hours as a function of thickness and top skirt OD.
Flange Costs -- pricing for flanges. Slip on, lap joint, threaded and socket welded
flange costs are based on material and class as a function of flange size. Long
weld neck and blind flange costs are based on material, class, and facing as a
function of flange size. Weld neck flange costs are based on material, class, bore
size (to fit pipe schedule listed), and flange facing as a function of flange size.
Flange Cutting Fee (LWN) -- pricing for cutting long weld neck flanges to the
required length as a function of flange type and flange size.
Flange Specs (LWN) -- displays standard length and cost per 1" lengths as a
function of flange size and class.
Flange to Nozzle - Fitup Labor -- labor hours to fitup flange to nozzle based on
pipe schedule as a function of flange type, metallurgy, and nozzle OD (nominal
size is also included for informational purposes only). Fields must not be added
or deleted from these tables.
Flange to Nozzle - Welding Labor -- labor hours for welding the flange to nozzle
based on pipe schedule as a function of flange type, metallurgy, and nozzle OD
(nominal size is also included for informational purposes only). Fields must not
be added or deleted from these tables.
Gasket Cost -- cost per gasket as a function of gasket type, flange nominal size,
and class (used with ASME B16.5/16.47 flanges).
APPENDIX A
Grinding Labor -- grinding labor rates as a function of metallurgy, grinding type

(normal, flush, smooth), and component thickness.
Head Bevel Labor -- labor hours to bevel heads as a function of head thickness
and head OD.
Head Costs -- pricing for heads as a function of material, head nominal thickness
and head OD.
Head Flat Fitup Labor -- labor hours to fitup flat welded heads -- sketch (c), (e),
(f), (g), (h) -- as a function of head nominal thickness and head OD.
Head Flat Layout Labor -- labor hours to lay out flat welded heads as a function
of head nominal thickness and head OD.
Head Flat Machining Labor -- machining labor (minutes/ft) for flat welded heads
as a function of groove depth and head OD.
Legs Labor -- labor hours (layout/burn, fitup, welding) for legs as a function of
major dimension (larger of the leg section width and length).
Legs Labor - Base Plate -- labor hours (layout, fitup) for leg base plate as a
function of major dimension (larger of the leg base plate width and length).
Legs Labor - Pad -- labor hours (layout, fitup) for leg pad as a function of major
dimension (larger of the leg pad width and length).
Machining Labor -- labor hours for appendix 2 flanges as a function of flange
Material Properties -- includes material density, welding rod density, welding rod
cost, normalization premium, impact test and metallurgy for a specified material.
Misc Items 1 -- miscellaneous items to be added to the Miscellaneous section on
the Vessel Detail Cost sheet in the estimate. Includes material, quantity, weight,
material cost, consumables cost, fitup labor, cutting labor, layout labor, welding
labor, drilling labor, and installation or other labor.
Misc Items Auto -- miscellaneous items that Coster will add automatically to the
Miscellaneous section on the Vessel Detail Cost sheet in the estimate. Includes
material, quantity, weight, material cost, consumables cost, fitup labor, cutting
labor, layout labor, welding labor, drilling labor, and installation or other labor.
Miscellaneous Fabrication Labor -- miscellaneous fabrication operations as a
function of metallurgy and component thickness (includes cutting, fillet welding,
groove welding drilling and bevelling).
APPENDIX A
Nozzle to Shell or Head Labor -- labor hours to attach nozzle to shell or head
(layout, fitup) as a function of vessel thickness and nozzle OD.
Pad to Nozzle Labor -- labor hours to install pad to nozzle (layout, fitup) as a
function of pad thickness and nozzle OD.
Painting (finish) -- includes application labor, paint cost, coverage, and standard
container size for each paint type.
Pipe Cost Schedule -- pricing for pipe according to pipe material and pipe
schedule as a function of pipe nominal size.
Plate Costs -- pricing for plate as a function of plate material, plate width, and
plate thickness.
Platform/Ladder Cost and Labor -- material cost and labor hours for platforms,
railings, and ladders.
Primer -- includes application labor, primer cost, coverage, and standard
container size for each primer type.
Ring Joint R Cost -- unit cost as a function of material and R number (used with
ASME B16.5/16.47 flanges).
Ring Joint RX Cost -- unit cost as a function of material and RX number (used
with ASME B16.5/16.47 flanges).
Saddles Fitting Labor -- labor hours to fit the saddle and wear plate as a function
of vessel OD.
Stock Plate Sizes (English Units or Metric Units) -- list of standard plate sizes
available for cutting components. Includes available metallurgy for standard
plate sizes as a function of plate thickness and plate dimensions -- width and
length.
Structures/Rings/Tray Supports Material Costs -- pricing for structures/rings/tray
supports as a function of material, type, and size.
Stud Cost -- stud cost (including 2 hex nuts) as a function of stud material, stud
bolt length and stud diameter (used with ASME B16.5/16.47 flanges).
Tray Installation Labor -- labor hours to install tray support rings (layout) as a
function of vessel ID.
Vacuum Ring Labor -- labor hours to roll and fit up vacuum rings as function of
vessel OD.
APPENDIX A
Weld Deposition Rate - Circumferential Seam Weld -- weld deposition rate (lb/
hour) as a function of component thickness and metallurgy. There is also a full
rework multiplier which is used to increase the labor hours for full joint
examination. This multiplier varies according to thickness.
Weld Deposition Rate - Longitudinal Seam Weld -- weld deposition rate (lb/hour)
as a function of component thickness and metallurgy. There is also a full rework
multiplier which is used to increase the labor hours for full joint examination.
This multiplier varies according to thickness.
Weld Deposition Rate - Nozzle Fillet Weld -- fillet weld deposition rate (lb/hour)
for manual welding as a function of metallurgy, weld leg size, and nozzle OD.
For outer fillet welds, the deposition rate is based on the pad OD (in).
Weld Deposition Rate - Nozzle Groove Weld -- groove weld deposition rate (lb/
hour) for manual welding as a function of metallurgy, weld thickness and nozzle
OD.
Weld Reinforcement -- weld bead reinforcement -- height of the weld bead
projecting beyond the surface of the parts being joined as a function of component
material thickness and the type of seam.
Welding Time - Circumferential Seam Weld -- This table contains min/ft welding
rates based on thickness, metallurgy and weld type. The values from this table are
converted to lb/hour weld deposition rates and are used to populate the Weld
Deposition Rate - Circumferential Seam Weld table which is used during the
costing process to calculate welding labor hours. There is also a full rework
multiplier based on the thickness (included to increase the labor hours for full
joint examination) which will be transferred from the welding time table to the
weld deposition rate table when the lb/hour conversions are made. The Welding
Time - Circumferential Seam Weld table is NOT used during the costing process.
It is available only as a conversion tool for users who have labor hours based on
welding time rather than weld deposition rate.
Welding Time - Longitudinal Seam Weld -- This table contains min/ft welding
rates based on thickness, metallurgy, and weld type. The values from this table
are converted to lb/hour weld deposition rates and are used to populate the Weld
Deposition Rate - Longitudinal Seam Weld table which is used during the costing
process to calculate welding labor hours. There is also a full rework multiplier
based on the thickness (included to increase the labor hours for full joint
examination) which will be transferred from the welding time table to the weld
deposition rate table when the lb/hour conversions are made. The Welding
Time - Longitudinal Seam Weld table is NOT used during the costing process. It
is available only as a conversion tool for users who have labor hours based on
welding time rather than weld deposition rate.
APPENDIX A
Welding Time - Nozzle Fillet Weld -- This table contains min/ft welding rates as a
function of metallurgy, weld leg size, and nozzle OD. The values from this table
are converted to lb/hour weld deposition rates and are used to populate the Weld
Deposition Rate - Nozzle Fillet Weld table which is used during the costing
process to calculate welding labor hours. The Welding Time - Nozzle Fillet Weld
table is NOT used during the costing process. It is available only as a conversion
tool for users who have labor hours based on welding time rather than weld
deposition rate.
Welding Time - Nozzle Groove Weld -- This table contains min/ft welding rates
as a function of metallurgy, weld thickness, and nozzle OD. The values from this
table are converted to lb/hour weld deposition rates and are used to populate the
Weld Deposition Rate - Nozzle Groove Weld table which is used during the
costing process to calculate welding labor hours. The Welding Time - Nozzle
Groove Weld table is NOT used during the costing process. It is available only as
a conversion tool for users who have labor hours based on welding time rather
than weld deposition rate.
INDEX
13
2 to 1 HEAD
calculations 11-27
ALIAS
add names 7-2
clear alias list 7-2
coupling materials 3-7, 7-2
delete names 7-2
flange materials 3-7, 7-3
lists 7-1
matching material names 3-5
material 3-2, 3-6
name 3-6
pipe materials 3-6, 7-2
plate materials 3-5, 7-1
APPENDIX 2 FLANGE
calculations, body flange 11-35
ASME B16.5/16.47 FLANGE 6-2
calculations, body flange 11-35
hydrotest, body flange 11-35
impact testing, body flange 11-94
labor hours/costs, body flange 11-36
material cost, body flange 11-36
normalization, body flange 11-94
ATTACHMENTS 8-7
BACKUP COSTER DATA 4-5
BACKUP FILES
directory 4-6
BASE PLATE
labor hours 5-5
legs 11-91
BEVEL
cylinder 11-19, 11-22
skirt 11-67
BEVEL ANGLE
nozzle groove welds 7-12
BEVEL LABOR
heads 5-2, 11-27, 11-28
BILL OF MATERIALS 7-7, 7-14, 8-15
cutting sketch 8-16
plate sizes 11-14
plate usage 8-17
radiography 8-17
weight of source material 8-16
BLASTING 7-5
calculations 11-95
BLASTING/CLEANING
cylinder 11-16
heads 11-27, 11-29
method 4-3
skirt 11-65
skirt base ring 11-53
INDEX
transition 11-20
BLIND
cost 8-11
flange 8-11
flange table 5-3
labor hours 8-11
long weld neck 11-73
nozzles 11-72
BOLTUP BLINDS 5-3
BUTT WELDING
vacuum rings 11-23
CALCULATIONS
appendix 2 body flange 11-35
asme b16.5/16.47 body flange 11-35
blasting/cleaning 11-95
cylinder 11-16
cylinder, purchased 11-16
davits 11-94
grinding 11-95
heads 11-27, 11-29
hydrotest 11-96
impact testing 11-93
insulation/lining 11-44
legs 11-87
normalization 11-93
nozzles 11-68
packed bed 11-41
pads 11-80
paint 11-96
platform/ladder/top head platform 11-41
primer 11-96
pwht 11-97
saddles 11-46
skirt 11-64
transition 11-20
tray support 11-42
vacuum rings 11-23
welding 11-10, 11-97
x-ray 11-97
CENTERED BOLTING CHAIR
CIRCUMFERENTIAL SEAM WELDING
see also girth seam labor
skirt 11-65
transition 11-20
CLEANING 7-5
calculations 11-95
method 4-3
CODEWARE
vessel file 4-1
< INDEX - i >
INDEX
COLUMN
estimate 8-7
misc section 8-12
nozzle section 8-9
shell section 8-7
COMPATIBILITY
vessel files 1-1
COMPONENT
bill of materials 8-15
COMPRESS 3-1
files compatible with Coster 1-1
CONSUMABLES
cost 8-12
CONVERSIONS
currency 8-2
units 8-2
COPYRIGHT i
COSTER
official material 3-6
quick start 2-1
spreadsheet template file (CostSS.xls) 8-2
COSTS
finished vessel 8-14
finished weight plate material 8-14
total plate material 8-14
total vessel costs 8-15
unused plate material 8-14
vessel totals 8-14
COUPLING 6-1, 8-7
alias 7-1
alias list 3-7
alias names 7-2
layout/fitup 5-2
to vessel 5-2
CROSS REFERENCE
material names 3-6
CURRENCY 7-3, 7-4, 8-3
database tables 8-6
estimate 11-1
revising on tables 3-9
CUSTOM
cut plate materials 7-14
plate layout, conical skirts 11-14
plate layout, cylinders 11-14
plate layout, nozzles 11-14
plate layout, skirt base rings 11-15
plate layout, skirts 11-14
plate layout, transitions 11-14
CUSTOMIZE
Coster 3-1
Coster template (CostSS.xls) 8-2
cutting plate material 11-13
database tables 3-2
misc items 8-2
< INDEX - ii >
report 8-18
CUT WIDTH 7-6
CUTTING 8-13
alternate layout 11-13
conical sections 11-6
cylinder 11-18
labor hours (nozzle) 8-11
labor hours (pad) 8-11
labor, head 11-30
labor, skirt 11-66
labor, transition 11-21
length, custom cut transitions and conical skirts
11-15
length, cylinder 11-16
length, skirt 11-64
long weld neck 6-2, 6-3
plate layout 11-3
sketches 11-9
skirt base rings 11-9
skirt base rings, custom cut 11-15
transition 11-20
CUTTING SKETCH
display on estimate 7-9
CYLINDER
bevelling 11-19, 11-22
calculations 11-16
custom cut plates 7-14
cutting 11-18
cutting length 11-16
fitup labor 11-17, 11-18
forming 11-18
girth seam labor 11-19
grinding 11-16
impact test 11-16
long seam labor 11-19
material cost 11-16, 11-17
method for estimating 7-8
normalization 11-16, 11-94
pipe 11-16, 11-17
plate 11-16, 11-17
properties 11-16
purchased 11-16, 11-17
surface area 11-19
welding 11-16
DATABASE
see also tables
backup file (CostDbBk.mdb) 4-6
changing database 7-8, 7-9
current database for estimating 10-1
global update 3-9
password 3-10
INDEX
regional settings 3-10

revising currency 3-9
revising units 3-9
DATABASE TREE 9-1
DAVITS 5-3
add 7-8
calculations 11-94
material cost 6-5
minimum manway diameter 7-7
user defined default 5-4
DEFAULTS
active cost source database 7-8
active cost source directory 7-9
active cost source drive 7-9
alias lists dialog 7-1
always add davits 7-8, 11-94
bevel angle (nozzle groove welds) 7-12
blasting/cleaning dialog 7-5
clip labor, insulation 7-3
clip labor, insulation/lining 11-44
clips 7-3
clips, insulation 7-3
clips, insulation/lining 11-44
coupling alias materials 7-2
coverage, insulation 7-3
coverage, insulation/lining 11-44
currency 7-4
currency/exchange dialog 7-3
custom plates 7-14
cylinder 7-8
defined names 8-2
design program to use for materials list 7-9
diameter 7-14
diameter/longitudinal weld seams ratio dialog 7-13
display cutting sketch on estimate 7-9
exchange rate 7-4
fabrication 7-6
field installed insulation 7-3
field installed, insulation 7-3
fillet weld 7-14
fillet weld size for vessel internals 7-14
finishing 7-5
flange alias materials 7-3
hydrotest dialog 7-5
hydrotest factors 7-5
insulation clips dialog 7-3
labor rate 7-8
labor tables 5-1
lining 7-3
lining clips dialog 7-3
manufacturing labor rate 7-8
material tables 6-1
maximum allowable plate length 7-7
maximum allowable plate width 7-7

menu 2-2, 7-1
menu units 7-4
min. manway diameter to add davits 7-7, 11-94
minimum shell course length 7-6
number of long seams 7-14, 11-14
operator weld efficiency 7-12
other defaults dialog 7-6
paint application labor 5-4
paint cost 5-4
paint coverage 5-4
paint labor rate 7-8
paint standard container size 5-4
pipe alias materials 7-2
pipe material waste 7-7
pipe minimum cut length 7-7
plate alias materials 7-1
plate layout 11-3
post weld heat treatment 7-7
primer labor rate 7-8
print expanded form of estimate 7-9
program output 7-8
report currency 7-4
saddle fillet weld size 7-14, 11-46
saddle welding 7-15
sandblasting labor rate 7-8
set user defined 7-1
shop installed insulation 7-3
shop installed, insulation 7-3
square all sides of plate 7-8
switch from single to double welding 7-10
tables 3-2
tray supports 7-10
tray supports deposition rate 7-14
type of welding 7-10
u groove weld radius 7-12
use custom plates cut to component size 11-13
vacuum ring fillet weld size 7-14
vacuum ring intermittent welding 7-14, 11-23
vacuum ring weld deposition rate 7-14
vacuum ring welding 7-15, 11-23
waste from flame cutting 7-6
weld bevel angle 7-11
weld detail dialog 7-10
weld gap 7-10
weld recovery 7-12
weld straight section 7-11
welding 7-10
welding labor rate 7-8
wire brush labor rate 7-8
DEFINED NAMES
see also range names
adding 8-3
view list 8-4
< INDEX - iii >
INDEX
DESCRIPTION
DESIGN PROGRAM
materials list 7-9
DIALOGS
purpose 3-1
DIAMETER/LONGITUDINAL WELD SEAMS RATIO
7-13
DOUBLE BASE RING
DRILLING 8-13
DROP FROM
ERROR MESSAGE
key not found 1-1
printer not found 8-1
uninstalling 1-2
ESTIMATE
add misc items 8-1
bill of materials 2-1, 8-15
columns 8-7
currency 7-4, 8-3, 11-1
customize template 8-18
cutting sketches 2-1
drop material remaining 8-17
drop material used 8-17
Excel compatible 3-1
finished vessel cost 8-14
finished weight plate material cost 8-14
format cells 8-3
girth seams added 3-4
headings 8-3, 8-6
miscellaneous section 8-12
nozzle section 8-9
plate usage 2-1, 8-17
print expanded form 7-9
printing 8-1
radiography 8-17
radiography table 2-1
scrap material 8-17
sections 2-1
shell section 8-7
spreadsheet 8-6
spreadsheet operation 8-1
starting 2-1
stock plates required 8-17
summary report 2-1, 8-18
total cost 2-1
total finished vessel weight 8-14
total plate material cost 8-14
total unused material cost 8-17
total vessel costs 8-15
units 8-3, 11-1
< INDEX - iv >
unused plate material cost 8-14

user defined plates required 8-17
version 8-3
vessel total costs 8-14
x-ray cost 8-14
ESTIMATING METHOD
skirt base ring 11-52, 11-60
EXCEL
version compatibility with Coster 8-3
EXCHANGE RATE 7-3, 7-4
F&D HEAD
calculations 11-27
F3 2-1
FABRICATION 7-6
FACING
flange 4-3
FEATURES
backup Coster data 4-5
cost a Codeware file 4-1
coupling alias list 3-7
customize summary report 2-1
delete field 3-8
delete record 3-7
flange alias list 3-7
insert field 3-7
insert record 3-7
interpolation 2-1, 8-6
pipe alias list 3-6
plate alias list 3-5
plate selection 3-2
print database table 3-7
repair Coster database 4-6
retrieve Coster estimate 4-5
split database view 3-8
summary report 2-1
user defined defaults 2-2
vessel detail cost 2-1
FIELD
delete 3-8
insert 3-7
FIELD INSTALLED
FILE MENU 4-1
add miscellaneous items (database) 8-2
backup Coster data 4-5
cost a Codeware file 4-1
repair Coster database 4-6
retrieve Coster estimate 4-5
FILES
.xls 4-5
backup (database/template) 4-6
compatible with Coster 1-1
compatible with Coster (.xml output) 1-1
INDEX
CostDbBk.mdb 4-6
Coster directories 10-1
CostSS.xls 8-2
CostSsBk.xls 4-6
sample vessel 4-1
sample1 2-1
FILLET WELD 7-14
legs 11-87
saddle 7-14, 11-46
vacuum ring 7-14
vessel internals 7-14
FINISHING 5-4, 6-5, 7-5
paint 5-4
primer 5-4
FITTINGS 6-1
FITUP LABOR 5-1, 8-12
cylinder 11-18
flange to nozzle 5-3
heads 11-28, 11-31
non-scheduled nozzles 11-74
scheduled nozzles 11-74
skirt 11-66
transition 11-21
FLAME CUTTING WASTE 7-6
FLANGE
alias 7-1
alias list 3-7
alias names 7-3
cost 8-11
cutting fee, long weld neck 6-3
facing 4-3
labor hours 8-11
nozzle section, flange type 8-9
nozzles 11-72
standard cost/labor 11-73
welding labor 11-76
FLANGE COST
appendix 2 11-36, 11-73
ASME B16.5/16.47 11-36
FLAT HEAD
calculations 11-29
FORMED HEADS 6-4
FORMING LABOR
cylinder 11-18
cylinder table 5-1
fabricated nozzles 8-11
skirt 11-66
skirt (straight) table 5-1
transition 11-20, 11-21
transition/conical skirt table 5-2
vacuum rings 11-23
FORMULAS
entering 8-1
miscellaneous items 8-2

FUNCTION KEYS
F3 2-1
GASKETS
cost table 6-5
material 4-3
GIRTH SEAM LABOR
see also circumferential seam welding
cylinder 11-19
heads 11-28
transition 11-22
GIRTH SEAMS
added 3-4
GLOBAL UPDATE
revise database values 3-9
GRINDING
calculations 11-95
cylinder 11-16
heads 11-27, 11-29
inside 4-3
outside 4-3
rates 5-3
skirt 11-65
transition 11-20
HARDWARE
key 1-1
program activator 1-1
requirements 1-1
HEADS
bevel labor 5-2, 11-27, 11-28
blasting/cleaning 11-27, 11-29
calculations 11-27, 11-29
circumferential seam welding 11-27
cutting labor 11-30
grinding 11-27, 11-29
impact test 11-27, 11-29
labor cost 11-30
labor hours 11-30
layout labor 11-31
long seam labor 11-28, 11-34
machining labor 11-31
normalization 11-94
properties 11-27, 11-29
surface area, 2 to1 11-28
surface area, f&d 11-28
surface area, flat 11-34
surface area, hemispherical 11-29
welding labor 11-31
HELP MENU 10-1
about Coster 10-1
< INDEX - v >
INDEX
Coster directories 10-1

database name 10-1
HEMISPHERICAL HEAD
calculations 11-27
HILLSIDE
see also nonradial
nozzles 11-77
pad plate size 11-81
HISTORY
printing ii
HYDROTEST 7-5, 8-12
calculations 11-96
factor a,b,c 7-5
labor 5-3
long weld neck 11-73
nozzles 11-72
IDENTICAL
attachments 8-12
nozzles 8-10
IDENTIFIER 8-9, 8-12, 8-15, 8-16
IMPACT TEST
cylinder 11-16
heads 11-27, 11-29
saddles 11-46
skirt 11-64
transition 11-20
vacuum rings 11-23
IMPACT TESTING
calculations 11-93
cylinder 11-94
heads 11-94
nozzles 11-94
INSERT
miscellaneous items 8-1
INSTALL/OTHER 8-13
INSTALLATION 1-1
Coster files 1-1
hardware key 1-1
network 1-1
system requirements 1-1
INSULATION 3-11, 7-3
calculations 11-44
clip labor 7-3
clips 7-3
coverage 7-3
field/shop installed 11-44
labor costs 11-45
labor hours 11-45
material cost 11-45
shop installed 7-3
< INDEX - vi >
INTERPOLATION 2-1, 2-2

method 11-2
multiple 11-2
single 11-2
ITEM
nozzle section 8-9
shell section 8-7
LABOR COSTS
heads 11-30
nozzle section 8-11
saddles 11-51
shell section 8-9
tray support 11-44
vacuum rings 11-26
LABOR HOURS
attach blind flange 5-3
blast 8-9
blind 8-11
clean 8-9
cutting 8-13
cutting (nozzle) 8-11
cutting (pad) 8-11
drilling 8-13
fitup 8-12
flange 8-11
flange welding 8-11
form and tack cylinder 2-2
form cylinders 5-1
form fabricated nozzles 5-1
form straight skirts 5-1
forming 8-11
grind 8-9
heads 11-30
install couplings 5-2
install/other 8-13
layout 8-13
layout/cut/install pad 5-3
legs 11-90
long seam welding 8-11
miscellaneous section (cutting) 8-13
miscellaneous section (drilling) 8-13
miscellaneous section (fitup) 8-12
miscellaneous section (install/other) 8-13
miscellaneous section (layout) 8-13
miscellaneous section (welding) 8-13
nozzle section 8-11
INDEX
nozzle section (nozzle) 8-11

nozzle section (pad) 8-11
nozzle to shell or head 5-3
nozzle welding 8-11
pad welding 8-11
platform/railing/ladder/top head platform 11-42
saddles 11-51
shell section 8-9
shell section bevel 8-8
shell section cutting 8-8
shell section forming 8-8
shell section forming, fitup, cutting 8-8
shell section girth seam 8-8
shell section long seam 8-7
skirt 11-67
tray support 11-44
vacuum rings 11-26
welding 8-13
LABOR MENU
boltup blinds 5-3
coupling to vessel 5-2
davit 5-3
finishing 5-4
fitup 5-1
fitup labor - cylinder/cylinder 5-1
fitup labor - cylinder/transition 5-1
fitup labor - flat welded head sketch (c), (e), (f),
(g), (h) 5-1
fitup labor - head/cylinder includes formed heads
and flat welded heads sketch (b-1), (b2), (d) 5-1
fitup labor - nonradial nozzle factor 5-1
fitup labor - skirt 5-1
forming (cylinder/straight skirt) 5-1
forming (transition/skirt) 5-2
grinding rates 5-3
head bevel 5-2
layout - flat welded head 5-2
legs 5-4
legs labor 5-4
legs labor - base plate 5-4
legs labor - pad 5-4
machining - flat welded head 5-2
nozzle installation 5-2
nozzle/long weld neck 5-3
pad to nozzle/long weld neck 5-3
platform/ladder 5-5
saddles 5-5
skirt base ring (layout) 5-5
tray support rings 5-5
vacuum rings 5-2
welding 5-6
LABOR RATE 7-8

welding 7-8
LABOR TABLES
base plate layout labor 5-5
blind flange labor 5-3
cones forming labor 5-2
conical skirts forming labor 5-2
coupling installation labor 5-2
davit labor 5-3
davit weight 5-3
drilling 5-3
flange to nozzle fitup labor 5-3
flange to nozzle welding labor 5-3
grinding 5-3
head bevel labor 5-2
head layout labor (flat welded head) 5-2
head machining labor (flat welded head) 5-2
machining 5-3
misc fabrication 5-3
nozzle to shell or head labor 5-3
pad to nozzle labor 5-3
platform/ladder cost and labor 5-5
saddles fitting labor 5-5
transition forming labor 5-2
tray installation labor 5-5
vacuum ring labor 5-2
LANGUAGE
regional settings 3-10, 8-1
LAYOUT
custom plate, cylinders 11-14
custom plate, nozzles 11-14
custom plate, skirt base rings 11-15
custom plate, skirts 11-14
LAYOUT LABOR 8-13
heads 11-31
LEGS 5-4
base plate 11-88, 11-91
calculations 11-87
fillet weld size 11-87
labor hours 11-90
major dimension 11-88
material cost 11-89
pad 11-88, 11-92
welding rod 11-90
LENGTH
circumferential seam weld 11-14, 11-15
longitudinal seam weld 11-14, 11-15, 11-16
LIBRARIES
labor 3-1
material 3-1
LICENSE AGREEMENT i
LINING 3-10
calculations 11-44
clips 7-3
< INDEX - vii >
INDEX
cost 3-10
field/shop installed 11-44
labor 3-10
labor costs 11-45
labor hours 11-45
material cost 11-45
LONG SEAM LABOR
cylinder 11-19
heads 11-28, 11-34
transition 11-22
LONG WELD NECK 6-2
attach to vessel 5-3
blind 11-73
cost 6-3
cutting fee 6-2, 6-3
flange costs 6-2
flange specs 6-2
hydrotest 11-73
length, standard 11-73
LONGITUDINAL SEAM WELDING
skirt 11-65
transition 11-20
LONGITUDINAL WELD SEAMS RATIO 7-13
MACHINING LABOR
heads 11-31
MAIN MENU 3-1
MAJOR DIMENSION
legs 11-88
legs, base plate 11-88
legs, pad 11-88
MANUFACTURING LABOR
cost 7-8
MATERIAL
alternate layout (custom cut) 11-13
head material costs 6-4
matching names 3-5
names 3-5
nozzle section 8-9
plate layout 11-9
plate layout (default method) 11-3
scrap, custom transitions and conical skirts 11-15
shell section 8-7
waste 7-7
MATERIAL COST
cylinder 11-17
heads 11-27, 11-30
legs 11-89
miscellaneous section 8-12, 8-14
nozzle section 8-12
< INDEX - viii >

nozzles 11-70, 11-76
pads 11-80
platform/railing/ladder/top head platform 11-42
saddles 11-50
shell section 8-7
skirt 11-66
tables 6-1
transition 11-20, 11-21
tray support 11-43
vacuum rings 11-23, 11-26
MATERIAL MENU
ASME B16.5/16.47 flanges 6-2
couplings/fittings cost 6-1
davit material cost 6-5
finishing 6-5
flange specs table 6-3
formed heads 6-4
gasket cost 6-5
long weld neck 6-2
material properties 6-4
misc items 6-4
misc items 1 6-4
pipe cost 6-4
platform/ladder 6-6
ring type joint r cost 6-6
ring type joint rx cost 6-6
stock plate sizes 6-5
structures/rings/tray supports cost 6-4
stud cost 6-6
MATERIAL TABLES
couplings costs 6-1
cylinder costs (purchased formed/tacked) 6-1
cylinder costs (purchased welded) 6-1
davit cost 5-3
gasket cost 6-5
head 2 to 1 material costs 6-4
head hemi material costs 6-4
material properties 6-4
misc items 1 6-4
misc items auto 6-5
paint 6-5
pipe cost schedule 6-4
plate material costs 6-4
platform/ladder cost and labor 6-6
primer 6-5
stock plate sizes 6-5
structures/rings/tray supports material costs 6-4
stud cost 6-6
MENU BAR
INDEX
main menu 3-1

MENUS
database tree 9-1
defaults menu 7-1
file menu 4-1
help menu 10-1
labor menu 5-1
material menu 6-1
spreadsheet 8-1
METALLURGY 3-3
MISC ITEMS 6-4
auto 6-5
currency conversion 8-2
insert 8-1
units conversion 8-2
MISC SECTION 8-2, 8-7, 8-12
costs 8-2
MULTIPLIER
full joint examination 5-8
NEUTRAL AXIS
vacuum rings 11-23
NONRADIAL
see also hillside
nozzles 11-77
NORMALIZATION
calculations 11-93
cylinder 11-16, 11-94
heads 11-27, 11-29, 11-94
nozzles 11-94
saddles 11-46
skirt 11-64
transition 11-20
vacuum rings 11-23
NOZZLES 8-7
attach to vessel 5-3
bevel angle (groove welds) 7-12
blind cost/labor 11-72
calculations 11-68
custom cut plates (fabricated nozzles) 7-14
estimate 8-7, 8-9
flange cost/labor 11-72
hillside 11-77
hydrotest 11-72
installation labor 8-11
installation menu item 5-2
layout/cutting/fitup 5-3
length 7-7, 8-10
material costs 11-70
nonradial 11-77
non-scheduled 11-74
normalization 11-94
pad calculations 11-80
pipe material cost 11-76
plate material cost 11-76
properties 11-70
scheduled 11-74
tag 8-9
total cost 8-12
weld calculations 11-81
OPERATOR
weld efficiency 7-12
OVERVIEW
Coster 2-1
PACKED BED
calculations 11-41
weight 11-41
PAD 8-16
attach to long weld neck 5-3
attach to nozzle 5-3
calculations 11-80
hillside plate size 11-81
installation time 8-11
layout/cutting/install 5-3
legs 11-92
material 8-9
material waste 7-6
plate size 11-80
properties 11-80
radial plate size 11-81
PAINT
application labor 5-4
calculations 11-96
coats 4-2
cost 5-4
coverage 5-4
inside 4-2
labor cost 7-8
labor menu 5-4
outside 4-2
remaining 5-4
stainless steel materials 4-2
standard container size 5-4
PARALLEL
port 1-1
PASSWORD
database 3-10
PIPE
alias 7-1
alias list 3-6
alias names 7-2
cost 6-4
cylinder 11-16
material cost, nozzles 11-76
< INDEX - ix >
INDEX
material waste 8-15

minimum cut length 7-7, 8-15
schedules 6-4
waste 7-7
PLATE
alias 7-1
alias list 3-5
alias names 7-1
availability 3-4
custom cut 7-14, 11-13
cylinder 11-16
drop material remaining 8-17
drop material used 8-17
layout 11-3
layout, conical skirts 11-14
layout, fabricated cylinders 11-14
layout, fabricated nozzles 11-14
layout, skirt base rings 11-9, 11-15
layout, skirts 11-14
layout, transitions 11-14
material cost, nozzles 11-76
materials 7-2
maximum allowable length 7-7, 11-15
maximum allowable width 7-7, 11-15
minimum shell course length 7-6
quantity (bill of materials) 8-16
saddle layout 11-46
scrap material 8-17
size (bill of material) 8-16
size required 8-16
stock 11-16
stock required 8-17
unused material 8-17
user defined 3-4
user defined required 8-17
user defined size 11-14
plate 11-10
PLATFORM/LADDER/TOP HEAD PLATFORM
cage weight 11-41
calculations 11-41
interpolation 11-41
labor hours 11-42
ladder weight 11-41
material cost 11-42
square footage 11-41
table 5-5, 6-6
POST WELD HEAT TREATMENT
see PWHT 4-3, 11-97
PRIMER
calculations 11-96
coats 4-2
inside 4-2
< INDEX - x >
labor cost 7-8

labor menu 5-4
outside 4-2
stainless steel materials 4-2
PRINTER
parallel port 1-1
PRINTING
Coster estimate 8-1
database table 3-7
expanded form of estimate 7-9
print expanded form of estimate 8-1
spreadsheet error message 8-1
PROGRAM ACTIVATOR 1-1
PROGRAM OUTPUT 7-8
PROPERTIES
heads 11-27, 11-29
nozzles 11-70
pads 11-80
saddles 11-46
skirt 11-64
transition 11-20
tray support 11-42
vacuum rings 11-23
PURCHASED CYLINDERS 11-16
PWHT
calculations 11-97
defaults 7-7
dialog 4-3
QUANTITY
nozzle section 8-10
saddles 11-46
shell section 8-7
RADIAL
RAISED FACE
flange facing 4-3
RANGE NAMES
see also defined names
RECORD
delete 3-7
insert 3-7
REGIONAL SETTINGS
database tables 3-10
spreadsheet 8-1
REPAIR
Coster database 4-6
REPORT CURRENCY 7-4
RETRIEVE COSTER ESTIMATE 4-5
file name 4-5
files 4-5
REVISE ALIAS LISTS 7-1
INDEX
RING TYPE 4-3

flange facing 4-3
R 4-3
R cost table 6-6
RX 4-3
RX cost table 6-6
SADDLES 5-5
calculations 11-46
fillet weld size 7-14, 11-46
impact test 11-46
inside rib width 11-46
labor costs 11-51
labor hours 11-51
material cost 11-50
normalization 11-46
plate layout 11-46
properties 11-46
quantity 11-46
saddle width 11-46
surface area 11-52
welding 11-50
SAMPLE
cost estimation 2-1
SANDBLASTING LABOR
cost 7-8
SECTION DIMENSIONS
SECTION QTY
SHELL MATERIAL COST
shell section 8-9
SHELL SECTION 8-7
columns for components 8-7
SHELL TOTAL COST
shell section 8-9
SHOP INSTALLED
SINGLE BASE RING
external chairs 11-55
no gussets 11-59
with gussets 11-54
SKIRT
bevel conical skirt 11-67
bevel cylindrical skirt 11-67
bevelling 11-67
calculations 11-64
cutting labor 11-66
fitup labor 11-66
forming labor 11-66
grinding 11-65
impact test 11-64
labor hours 11-67
material cost 11-66

normalization 11-64
properties 11-64
surface area 11-68
welding 11-65
SKIRT BASE RING 5-5
calculations 11-52
centered bolting chair 11-53, 11-58
double base ring 11-53, 11-57
estimating method 11-52
fillet weld size 11-53, 11-59
impact test 11-52
labor hours 11-59
normalization 11-52
one segment calculations 11-60
plate layout 11-9
properties 11-54
single base ring with external chairs 11-53, 11-55
single base ring with gussets 11-53, 11-54
single base ring with no gussets 11-59
surface area 11-54
trial and error estimating method 11-60
two to six segments calculations 11-61
wastage 7-6
welding 11-59, 11-64
SKIRTS
SPLIT VIEW
database 3-8
SPREADSHEET
see also Coster
see also template
general operation 8-1
template file (CostSS.xls) 8-2
SQUARE ALL SIDES OF PLATE
default 7-8
SQUARE FOOTAGE
STARTING
Coster quick start 2-1
STOCK PLATE SIZES 6-5
STRUCTURAL TYPE
tray support 11-42
STRUCTURES/RINGS/TRAY SUPPORTS
table 6-4
STUDS
cost table 6-6
material 4-3
SURFACE AREA
2 to1 heads 11-28
cylinder 11-19
f&d heads 11-28
< INDEX - xi >
INDEX
flat heads 11-34

hermispherical heads 11-29
saddles 11-52
shell section 8-7
skirt 11-68
transition 11-23
TABLES
see also database
6000# couplings costs A-1
base plate layout labor 5-5, A-1
blind flange labor 5-3, A-1
circ seam weld deposition rate 5-6, 5-8
cones forming labor 5-2
cones/skirts forming labor 11-20, 11-64, A-1
conical skirt forming labor 5-2
coupling costs 7-2
coupling installation labor 5-2, A-1
couplings costs 3-7, 6-1
create misc items 8-2
currency 8-6
cylinder costs (formed/tacked) A-1
cylinder costs (purchased formed/tacked) 6-1
cylinder costs (purchased welded) 6-1
cylinder costs (welded) A-1
cylinder forming 11-16
cylinder forming labor 2-2, 5-1, 11-64, A-1
cylinders costs (formed/tacked) 11-16
cylinders costs (welded) 11-16
davit cost 5-3, A-1
davit labor 5-3, A-2
davit weight 5-3, A-2
default 3-2
drilling 5-3
drilling labor A-2
fitup labor - cylinder/cylinder 5-1
fitup labor - cylinder/transition 5-1
fitup labor - flat welded head sketch (c), (e), (f),
(g), (h) 5-1
fitup labor - head/cylinder includes formed heads
and flat welded heads sketch (b-1), (b2), (d) 5-1
fitup labor - nonradial nozzle factor 5-1
fitup labor - skirt 5-1
fitup labor (cylinder/cylinder) A-2
fitup labor (cylinder/transition) A-2
fitup labor (head/cylinder) A-2
fitup labor (nonradial nozzles) A-2
fitup labor (skirt) A-2
flange costs A-2
flange cutting fee - long weld neck 6-3
flange cutting fee (lwn) A-2
< INDEX - xii >
flange specs 6-3

flange specs (lwn) A-2
flange to nozzle fitup labor 5-3, A-2
flange to nozzle welding labor 5-3
flat head fitup labor 11-31
flat head layout labor 11-31
flat head machining labor 11-31
gasket cost 6-5, A-2
global update 3-9
grinding 11-17
grinding labor 5-3
grinding rates A-3
grinding table 11-27, 11-29
head 2 to 1 material costs 6-4
head bevel labor 5-2, 11-27, A-3
head costs 3-6, A-3
head f&d material costs 6-4
head flat fitup labor A-3
head flat layout labor A-3
head flat machining labor A-3
head hemi material costs 6-4
head layout labor (flat welded head) 5-2
head machining labor (flat welded head) 5-2
head, 2
1 material costs 7-2
head, f&d material costs 7-2
head, hemispherical material costs 7-2
insert field 2-2
insert record 2-2
labor 3-1
legs labor 5-4, 11-90, A-3
legs labor - base plate 5-4, 11-91, A-3
legs labor - pad 5-4, 11-92, A-3
listing A-1
long seam weld deposition rate 5-6, 5-8
machining 5-3
machining labor A-3
material 3-1
material properties 6-3, 6-4, 8-6, 11-16, A-3
misc fabrication 5-3, 11-16, 11-46, 11-51, 11-53,
11-59, 11-87, 11-92, 11-93
misc items 1 6-4, 8-2, A-3
misc items auto 6-5, A-3
miscellaneous fabrication labor A-3
nozzle fillet weld deposition rate 5-6, 5-8
nozzle groove weld deposition rate 5-6, 5-8
nozzle to shell or head labor 5-3, A-4
pad to nozzle labor 5-3, A-4
paint 5-4, 6-5
painting A-4
pipe cost schedule 6-4, A-4
plate material costs 2-1, 3-5, 3-6, 6-4, 7-2, 11-20,
11-88, A-4
INDEX
platform/ladder cost and labor 5-5, 6-6, 11-42, A-4

primer 5-4, 6-5, A-4
revising 8-6
revising currency 3-9
revising units 3-9
ring joint r cost A-4
ring joint rx cost A-4
saddles fitting labor 5-5, 11-46, 11-51, A-4
skirt (straight) forming labor 5-1
sorting records 2-2
stock plate sizes (english/metric) 6-5, 8-16, A-4
structures/rings/tray supports material costs 3-6,
6-4, 7-2, 11-23, 11-42, 11-88, A-4
stud cost 6-6, A-4
transition forming labor 5-2
tray installation labor 5-5, 11-42, A-4
units 8-6
vacuum ring labor 5-2, 11-23, A-4
weld deposition rate - circumferential seam 11-16,
A-5
weld deposition rate - longitudinal seam 11-16, A5
weld deposition rate - nozzle fillet weld 11-83, A-5
weld deposition rate - nozzle groove weld 5-8, 1183, A-5
weld deposition rate, circumferential seam 5-6, 58
weld deposition rate, longitudinal seam 5-6, 5-8
weld deposition rate, nozzle fillet weld 5-6, 5-8
weld deposition rate, nozzle groove weld 5-6
weld reinforcement 5-7, 7-13, A-5
welding time - circumferential seam A-5
welding time - longitudinal seam A-5
welding time - nozzle fillet weld A-6
welding time - nozzle groove weld A-6
welding time, circumferential seam 5-6, 5-7
welding time, longitudinal seam 5-6
welding time, longitudinal seams 5-7
welding time, nozzle fillet weld 5-6, 5-7
welding time, nozzle groove weld 5-6, 5-7
TEMPLATE
see also Coster
see also spreadsheet
Coster spreadsheet file (CostSS.xls) 8-2
TOTAL COST
nozzle section 8-12
vessel 8-15
TOTAL VESSEL COST 8-15
TOTAL VESSEL LABOR COST 8-15
TOTAL VESSEL LABOR HOURS 8-15
TOTAL VESSEL MATERIAL COST 8-15

TRADEMARKS ii
TRANSITION
calculations 11-20
cutting labor 11-21
fitup labor 11-21
forming labor 11-20, 11-21
grinding 11-20
impact test 11-20
long seam labor 11-22
normalization 11-20
properties 11-20
surface area 11-23
TRAY SUPPORTS 7-10
calculations 11-42
installation labor 5-5
labor costs 11-44
labor hours 11-44
material cost 11-43
properties 11-42
structural type 11-42
weight 11-44
weld deposition rate 7-14
U GROOVE
weld radius 7-12
UNINSTALLING 1-2
UNITS
database tables 8-6
defaults menu 7-4
estimate 8-3, 11-1
revising on tables 3-9
USE SQUARED PLATES
calculations 11-10
USER SELECTABLE ITEMS
cleaning method 4-3
cylinder 4-2
dialog 4-1
flange facing 4-3
gasket material 4-3
grinding inside 4-3
grinding outside 4-3
number of paint/primer coats 4-2
paint inside/outside 4-2
paint/prime stainless steel materials 4-2
primer inside/outside 4-2
ring type 4-3
stud material 4-3
USING COSTER 3-1
VACUUM RINGS 5-2
< INDEX - xiii >
INDEX
butt welding 11-23

calculations 11-23
Compress 5.x files 11-23, 11-24
Compress 6.x files 11-23, 11-25
fillet weld size 7-14
forming labor 11-23
impact test 11-23
intermittent welding 7-14
labor hours/costs 11-26
neutral axis 11-23
normalization 11-23
properties 11-23
roll and fitup 5-2
weld deposition rate 7-14
weld gap 11-23
welding 1 or 2 sides 7-15
VERIFICATION
calculations 11-1
cylinder 11-16
davits 11-94
grinding 11-95
heads 11-27, 11-29
hydrotest 11-96
legs 11-87
nozzle weld 11-81
nozzles 11-68
packed bed 11-41
pads 11-80
paint 11-96
post weld heat treatment 11-97
primer 11-96
saddles 11-46
skirt 11-64
transition 11-20
tray support 11-42
vacuum rings 11-23
welding 11-97
x-ray 11-97
VESSEL DETAIL COST 7-7
VESSEL FILE
compatible with Coster 1-1
VESSEL MODELER 3-1
WASTE
flame cutting 7-6
legs, base plate (flame cutting) 11-92
legs, pad (flame cutting) 11-93
pipe 7-7, 8-15
WEIGHT
< INDEX - xiv >
bill of materials (source material) 8-16

cage 11-41
cylinder (source material) 11-16
ladder 11-41
nozzle section (blind) 8-10
nozzle section (flange) 8-10
packed bed 11-41
shell section 8-7
source material, cylinder 11-16
source material, transition 11-20
total finished vessel 8-14
transition (source material) 11-20
tray support 11-44
WELD BEVEL ANGLE 7-11
WELD DEPOSITION RATE
circumferential seam 5-8
fillet/groove weld 5-8
longitudinal seam 5-8
tray supports 7-14
vacuum ring 7-14
WELD DETAIL 7-10
WELD EFFICIENCY
operator 7-12
WELD GAP 7-10
vacuum rings 11-23
WELD RADIUS
U groove 7-12
WELD RECOVERY 7-12
WELD REINFORCEMENT
table 7-13
WELD STRAIGHT SECTION 7-11
WELDING 5-6, 7-10, 8-13
bevel angle (nozzle groove welds) 7-12
calculations 11-97
circumferential seam 11-27
circumferential weld length 11-14, 11-15
conversion default values 5-6
convert welding time to deposition rate 5-7
cylinder 11-16
deposition rate 5-6
flange 8-11, 11-76
heads 11-31
intermittent 7-14
labor 2-2
labor cost 7-8
legs 11-90
long seam 8-11
longitudinal seam weld length 11-14, 11-15, 11-16
nozzle 8-11
nozzle calculations 11-81
operator weld efficiency 7-12
INDEX
pad 8-11
saddles 7-15, 11-50
single/double 7-10
skirt 11-65
tables used in calculations 5-6
time to weld 5-6
transition 11-20
type of welding 7-10
u groove weld radius 7-12
vacuum ring (1 side/2 sides) 7-15
vacuum ring fillet weld size 7-14
vacuum ring intermittent welding 7-14
weld bevel angle 7-11
weld gap 7-10
weld gap, vacuum rings 11-23

weld recovery 7-12
weld reinforcement 7-13
weld straight section 7-11
WELDING LABOR
WIRE BRUSH LABOR
cost 7-8
X-RAY
calculations 11-97
cost 8-14
dialog 4-4
total cost 4-5
< INDEX - xv >
INDEX
< INDEX - xvi >

Pressure Vessel Coster

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Pressure Vessel Coster

Загружено:

Авторское право:

Доступные форматы

VESSEL COSTER

3100 South Gessner Road Suite 610

< LICENSE AGREEMENT - i >

< LICENSE AGREEMENT - ii >

COSTER QUICK START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

USING COSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

FILE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

LABOR MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

MATERIAL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

< TABLE OF CONTENTS - i >

Cylinder Costs (purchased) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEFAULTS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

COSTER SPREADSHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

DATABASE TREE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

CALCULATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

< TABLE OF CONTENTS - ii >

< TABLE OF CONTENTS - iii >

< TABLE OF CONTENTS - iv >

Hardware Key Installation

Installing Coster Files

< INSTALLING COSTER 1 - 1 >

Uninstallating Coster Files

< INSTALLING COSTER 1 - 2 >

COSTER QUICK START

COSTER QUICK START

Review the Data Tables

< COSTER QUICK START 2 - 1 >

COSTER QUICK START

< COSTER QUICK START 2 - 2 >

How To Use Coster

Coster Main Menu

Coster Main Menu

< USING COSTER 3 - 1 >

Keys used in Coster:

F2 - Allows you to edit a cell within the spreadsheet.

Coster uses the following abbreviations when referring to metallurgy:

< USING COSTER 3 - 2 >

Standard Plate Material

< USING COSTER 3 - 3 >

Plate Material Size

< USING COSTER 3 - 4 >

Girth Seams Required

< USING COSTER 3 - 5 >

Standard Plate Material

< USING COSTER 3 - 6 >

Coupling Alias List

Navigating and Modifying the Database Tables

< USING COSTER 3 - 7 >

< USING COSTER 3 - 8 >

Revising Currency and/or Units on the Database Tables

< USING COSTER 3 - 9 >

< USING COSTER 3 - 10 >

< USING COSTER 3 - 11 >

< USING COSTER 3 - 12 >

Cost a Codeware File

< FILE MENU 4 - 1 >

User Selectable Items

< FILE MENU 4 - 2 >

Costing the Vessel

< FILE MENU 4 - 3 >

< FILE MENU 4 - 4 >

Total X-ray Cost

Retrieve Coster Estimate

Retrieve Coster Estimate